Powered surgical instruments with smart reload with separately attachable exteriorly mounted wiring connections

ABSTRACT

A modular surgical instrument system that comprises modular components and a control circuit electrically couplable to the modular components. The modular components comprise a shaft and a handle assembly. The handle assembly comprises a disposable outer housing. The disposable outer housing is movable between an open configuration and a closed configuration. The handle assembly further comprises a control inner core receivable inside the disposable outer housing in the open configuration. The disposable outer housing is configured to isolate the control inner core in the closed configuration. The modular components further comprise a loading unit releasably couplable to the shaft and a staple cartridge releasably couplable to an end effector. The loading unit comprises the end effector. The control circuit is configured to generate an interrogation signal, detect a response signal, determine a modular configuration of the modular surgical instrument system, and assess authenticity of the modular configuration.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

SUMMARY

In one aspect, the present disclosure provides a modular surgicalinstrument system that comprises modular components, comprising a shaftand a handle assembly releasably couplable to the shaft. The handleassembly comprises a disposable outer housing configured to define asterile barrier. The disposable outer housing comprises a firsthousing-portion and a second housing-portion movable relative to thefirst housing-portion between an open configuration and a closedconfiguration. The handle assembly further comprises a control innercore receivable inside the disposable outer housing in the openconfiguration. The disposable outer housing is configured to isolate thecontrol inner core in the closed configuration. The modular componentsfurther comprise a loading unit releasably couplable to the shaft,wherein the loading unit comprises an end effector. The modularcomponents further comprise a staple cartridge releasably couplable tothe end effector. The modular surgical instrument system furthercomprises a control circuit electrically couplable to the modularcomponents. The control circuit configured to generate an interrogationsignal, detect a response signal to the interrogation signal, determinea modular configuration of the modular surgical instrument system basedon the response signal, and assess authenticity of the modularconfiguration based on the response signal.

In another aspect, the present disclosure provides a modular surgicalinstrument system that comprises modular components characterized byunique identifier resistances. The modular components comprise a shaftand a handle assembly releasably couplable to the shaft. The handleassembly comprises a disposable outer housing configured to define asterile barrier. The disposable outer housing comprises a firsthousing-portion and a second housing-portion movable relative to thefirst housing-portion between an open configuration and a closedconfiguration. The handle assembly further comprises a control innercore receivable inside the disposable outer housing in the openconfiguration. The disposable outer housing is configured to isolate thecontrol inner core in the closed configuration. The modular componentsfurther comprise a loading unit releasably couplable to the shaft,wherein the loading unit comprises an end effector. The modularcomponents further comprise a staple cartridge releasably couplable tothe end effector. The modular surgical instrument system furthercomprises a control circuit electrically couplable to the modularcomponents. The authentication circuit is configured to detect a modularconfiguration of the modular surgical instrument system based on theunique identifier resistances and assess authenticity of the modularconfiguration.

In another aspect, the present disclosure provides a modular surgicalinstrument system that comprises modular components characterized byunique identifier resistances. The modular components comprise a shaftand a handle assembly releasably couplable to the shaft. The handleassembly comprises a disposable outer housing configured to define asterile barrier. The disposable outer housing comprises a firsthousing-portion and a second housing-portion movable relative to thefirst housing-portion between an open configuration and a closedconfiguration. The handle assembly further comprises a control innercore receivable inside the disposable outer housing in the openconfiguration. The disposable outer housing is configured to isolate thecontrol inner core in the closed configuration. The modular componentsfurther comprise a loading unit releasably couplable to the shaft,wherein the loading unit comprises an end effector. The modularcomponents further comprise a staple cartridge releasably couplable tothe end effector. The modular surgical instrument system furthercomprises a control circuit electrically couplable to the modularcomponents. The authentication circuit is configured to detect anidentification signal of a modular configuration of the modular surgicalinstrument system, measure a characteristic of the modularconfiguration, determine an authentication key based on at least onemeasurement of the characteristic of the modular configuration, andauthenticate the identification signal based on the authentication key.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 illustrates a perspective view of a surgical instrument system,in accordance with at least one aspect of the present disclosure.

FIG. 2 illustrates a perspective view of handle assembly of the surgicalinstrument system of FIG. 1 in a disassembled configuration, the handleassembly including an outer disposable housing and an inner core.

FIG. 3 illustrates a cross-sectional view of an electrical interface fortransmitting at least one of power and data between an end effector ofthe surgical instrument system of FIG. 1 and the inner core of FIG. 2 .

FIG. 4 is a logic flow diagram of a process depicting a control programor a logic configuration for electrically connecting an inner core of asurgical instrument system with a staple cartridge or an end effector,in accordance with at least one aspect of the present disclosure.

FIG. 5 is a graph illustrating drive member travel on the x-axis anddrive member speed on the y-axis, in accordance with at least one aspectof the present disclosure.

FIG. 6 is a graph illustrating drive member speed on the x-axis andmotor current on the y-axis, in accordance with at least one aspect ofthe present disclosure.

FIG. 7 is a partial elevational view of a surgical instrument system, inaccordance with at least one aspect of the present disclosure.

FIG. 8 is a partial elevational view of a surgical instrument system, inaccordance with at least one aspect of the present disclosure.

FIG. 9 is a cross-sectional view of a nozzle portion of the surgicalinstrument system of FIG. 8 .

FIG. 10 is a cross-sectional view of a handle assembly of a surgicalinstrument system, in accordance with at least one aspect of the presentdisclosure.

FIG. 11 is a cross-sectional view of a modular configuration of amodular surgical instrument system, in accordance with at least oneaspect of the present disclosure.

FIG. 12 is a graph illustrating resistance identifiers of variouspotential modular components of the modular surgical instrument system,in accordance with at least one aspect of the present disclosure.

FIG. 13 is a logic flow diagram of a process depicting a control programor a logic configuration for detecting and/or authenticating a modularconfiguration of a modular surgical instrument system or assembly.

FIG. 14 is a logic flow diagram of a process depicting a control programor a logic configuration for detecting and/or authenticating a modularconfiguration of a modular surgical instrument system or assembly.

FIG. 15 is a perspective view of a handle assembly of a modular surgicalinstrument system, the handle assembly including a disposable outerhousing and an inner core, in accordance with at least one aspect of thepresent disclosure.

FIG. 16 is a graph for assessing proximity and alignment of thedisposable outer housing and the inner core of FIG. 15 in an assembledconfiguration.

FIG. 17 is a perspective view of a surgical instrument system, inaccordance with at least one aspect of the present disclosure.

FIG. 18 is a cross-sectional view of a nozzle portion of a shaftassembly of the surgical instrument system of FIG. 17 .

FIG. 19 is a partial exploded view of components of the surgicalinstrument system of FIG. 17 .

FIG. 20 is a partial cross-sectional view of components of the surgicalinstrument system of FIG. 17 .

FIG. 21 is a logic flow diagram of a process depicting a control programor a logic configuration for disabling an inner core of a handleassembly of a surgical instrument system at an end-of-life event.

FIGS. 22-25 illustrate safety mechanisms for disabling a disposableouter housing of a handle assembly after usage in a surgical procedure,in accordance with at least one aspect of the present disclosure.

FIGS. 26-29 illustrate safety mechanisms for disabling a disposableouter housing of a handle assembly after usage in a surgical procedure,in accordance with at least one aspect of the present disclosure.

FIG. 30 is a perspective view of a surgical instrument system, inaccordance with at least one aspect of the present disclosure.

FIG. 31 is a partial cross-sectional view of an outer wall of a handleassembly of the surgical instrument system of FIG. 30 .

FIG. 32 is a simplified representation of a sterilization-detectioncircuit of the handle assembly of the surgical instrument system FIG. 30.

FIG. 33 is a top view of the handle assembly of the surgical instrumentsystem of FIG. 30 showing a light-emitting diode (LED) display thereof.

FIG. 34 is an expanded view of the LED display of FIG. 33 .

FIG. 35 is a graph illustrating sensor readings of a hydrogen peroxidesensor, in accordance with at least one aspect of the presentdisclosure.

FIG. 36 is a logic flow diagram of a process depicting a control programor a logic configuration for detecting an end of a lifecycle of are-serializable component of a surgical instrument system, in accordancewith at least one aspect of the present disclosure.

FIG. 37 illustrates a process of re-sterilizing a handle assembly of asurgical instrument system, in accordance with at least one aspect ofthe present disclosure.

FIG. 38 is a re-serialization system for re-sterilizing a handleassembly of a surgical instrument system, in accordance with at leastone aspect of the present disclosure.

FIG. 39 illustrates the re-serialization system of FIG. 38 in a closedconfiguration.

FIG. 40 is a re-serialization system for re-sterilizing a handleassembly of a surgical instrument system, in accordance with at leastone aspect of the present disclosure.

FIG. 41 is a primary electrical interface for use with a surgicalinstrument system, in accordance with at least one aspect of the presentdisclosure.

FIG. 42 is an actuator for use with a surgical instrument system, inaccordance with at least one aspect of the present disclosure.

FIG. 43 illustrates the actuator of FIG. 42 in different configurationsyielding different closure forces, in accordance with at least oneaspect of the present disclosure.

FIG. 44 is a graph illustrating different closure positions of an endeffector and corresponding closure forces as determine based on thedifferent configurations of FIG. 43 .

FIG. 45 is a perspective view of a disposable outer housing and an innercore of a handle assembly, in accordance with at least one aspect of thepresent disclosure.

FIG. 46 is a partial cross-sectional view of an actuator of the handleassembly of FIG. 45 .

FIG. 47 is a perspective view of a disposable outer housing and an innercore of a handle assembly, in accordance with at least one aspect of thepresent disclosure.

FIG. 48 is a partial cross-sectional view of an actuator of the handleassembly of FIG. 47 .

FIG. 49 is a graph vibrations, on the Y-axis, as a function of time onthe x-axis.

FIG. 50 is a partial exploded view of a handle assembly, in accordancewith at least one aspect of the present disclosure.

FIG. 51 is a partial cross-sectional view of an actuator of the handleassembly of FIG. 50 .

FIG. 52 is a partial exploded view of a handle assembly, in accordancewith at least one aspect of the present disclosure.

FIG. 53 is a partial exploded view of an actuator of a handle assembly,in accordance with at least one aspect of the present disclosure.

FIG. 54 is a partial cross-sectional view of the actuator of FIG. 53 .

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate certain embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application also owns the following U.S. PatentApplications that were filed on Dec. 2, 2020 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 17/109,589, entitled METHOD FOR        TISSUE TREATMENT BY SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2022/0168038;    -   U.S. patent application Ser. No. 17/109,595, entitled SURGICAL        INSTRUMENTS WITH INTERACTIVE FEATURES TO REMEDY INCIDENTAL SLED        MOVEMENTS, now U.S. Patent Application Publication No.        2022/0167980;    -   U.S. patent application Ser. No. 17/109,598, entitled SURGICAL        INSTRUMENTS WITH SLED LOCATION DETECTION AND ADJUSTMENT        FEATURES, now U.S. Patent Application Publication No.        2022/0167971;    -   U.S. patent application Ser. No. 17/109,615, entitled SURGICAL        INSTRUMENT WITH CARTRIDGE RELEASE MECHANISMS, now U.S. Patent        Application Publication No. 2022/0167972;    -   U.S. patent application Ser. No. 17/109,627, entitled DUAL-SIDED        REINFORCED RELOAD FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2022/0167981;    -   U.S. patent application Ser. No. 17/109,636, entitled SURGICAL        SYSTEMS WITH DETACHABLE SHAFT RELOAD DETECTION, now U.S. Patent        Application Publication No. 2022/0167973;    -   U.S. patent application Ser. No. 17/109,645, entitled SURGICAL        INSTRUMENTS WITH ELECTRICAL CONNECTORS FOR POWER TRANSMISSION        ACROSS STERILE BARRIER, now U.S. Patent Application Publication        No. 2022/0167982;    -   U.S. patent application Ser. No. 17/109,648, entitled DEVICES        AND METHODS OF MANAGING ENERGY DISSIPATED WITHIN STERILE        BARRIERS OF SURGICAL INSTRUMENT HOUSINGS, now U.S. Patent        Application Publication No. 2022/0167983;    -   U.S. patent application Ser. No. 17/109,651, entitled POWERED        SURGICAL INSTRUMENTS WITH EXTERNAL CONNECTORS, now U.S. Patent        Application Publication No. 2022/0167977;    -   U.S. patent application Ser. No. 17/109,667, entitled POWERED        SURGICAL INSTRUMENTS WITH COMMUNICATION INTERFACES THROUGH        STERILE BARRIER, now U.S. Patent Application Publication No.        2022/0167984; and    -   U.S. patent application Ser. No. 17/109,669, entitled POWERED        SURGICAL INSTRUMENTS WITH MULTI-PHASE TISSUE TREATMENT, now U.S.        Patent Application Publication No. 2022/0167975.

Applicant of the present application owns the following U.S. patentapplications, filed on Dec. 4, 2018, the disclosure of each of which isherein incorporated by reference in its entirety:

-   -   U.S. patent application Ser. No. 16/209,385, entitled METHOD OF        HUB COMMUNICATION, PROCESSING, STORAGE AND DISPLAY;    -   U.S. patent application Ser. No. 16/209,395, entitled METHOD OF        HUB COMMUNICATION;    -   U.S. patent application Ser. No. 16/209,403, entitled METHOD OF        CLOUD BASED DATA ANALYTICS FOR USE WITH THE HUB;    -   U.S. patent application Ser. No. 16/209,407, entitled METHOD OF        ROBOTIC HUB COMMUNICATION, DETECTION, AND CONTROL;    -   U.S. patent application Ser. No. 16/209,416, entitled METHOD OF        HUB COMMUNICATION, PROCESSING, DISPLAY, AND CLOUD ANALYTICS;    -   U.S. patent application Ser. No. 16/209,423, entitled METHOD OF        COMPRESSING TISSUE WITHIN A STAPLING DEVICE AND SIMULTANEOUSLY        DISPLAYING THE LOCATION OF THE TISSUE WITHIN THE JAWS;    -   U.S. patent application Ser. No. 16/209,427, entitled METHOD OF        USING REINFORCED FLEXIBLE CIRCUITS WITH MULTIPLE SENSORS TO        OPTIMIZE PERFORMANCE OF RADIO FREQUENCY DEVICES;    -   U.S. patent application Ser. No. 16/209,433, entitled METHOD OF        SENSING PARTICULATE FROM SMOKE EVACUATED FROM A PATIENT,        ADJUSTING THE PUMP SPEED BASED ON THE SENSED INFORMATION, AND        COMMUNICATING THE FUNCTIONAL PARAMETERS OF THE SYSTEM TO THE        HUB;    -   U.S. patent application Ser. No. 16/209,447, entitled METHOD FOR        SMOKE EVACUATION FOR SURGICAL HUB;    -   U.S. patent application Ser. No. 16/209,453, entitled METHOD FOR        CONTROLLING SMART ENERGY DEVICES;    -   U.S. patent application Ser. No. 16/209,458, entitled METHOD FOR        SMART ENERGY DEVICE INFRASTRUCTURE;    -   U.S. patent application Ser. No. 16/209,465, entitled METHOD FOR        ADAPTIVE CONTROL SCHEMES FOR SURGICAL NETWORK CONTROL AND        INTERACTION;    -   U.S. patent application Ser. No. 16/209,478, entitled METHOD FOR        SITUATIONAL AWARENESS FOR SURGICAL NETWORK OR SURGICAL NETWORK        CONNECTED DEVICE CAPABLE OF ADJUSTING FUNCTION BASED ON A SENSED        SITUATION OR USAGE;    -   U.S. patent application Ser. No. 16/209,490, entitled METHOD FOR        FACILITY DATA COLLECTION AND INTERPRETATION; and    -   U.S. patent application Ser. No. 16/209,491, entitled METHOD FOR        CIRCULAR STAPLER CONTROL ALGORITHM ADJUSTMENT BASED ON        SITUATIONAL AWARENESS.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

With reference to FIGS. 1-3 , a surgical instrument system is provided,such as, for example, an electromechanical surgical instrument system8500. System 8500 includes a handle assembly 8520, a plurality of typesof adapter or shaft assemblies such as, for example, shaft assembly8530, and a plurality of types of loading units or end effectors suchas, for example, end effector 8540. Handle assembly 8520 is configuredfor selective attachment thereto with any one of a number of shaftassemblies, for example, shaft assembly 8530 and, in turn, each uniqueshaft assembly 8530 is configured for selective connection with anynumber of surgical loading units or end effectors, such as, for example,end effector 8540. End effector 8540 and shaft assembly 8530 areconfigured for actuation and manipulation by handle assembly 8520. Uponconnecting one shaft assembly 8530, for example, to handle assembly 8520and one type of end effector such as, for example, end effector 8540 tothe selected shaft assembly 8530 a powered, hand-held, electromechanicalsurgical instrument is formed.

Various suitable loading units or end effectors for use with thesurgical instrument system 8500 are discussed in U.S. Pat. No.5,865,361, entitled SURGICAL STAPLING APPARATUS, and issued Feb. 2,1999, the disclosure of which is herein incorporated by reference in itsentirety. Various handle assemblies for use with the surgical instrumentsystem 8500 are discussed in U.S. Pat. No. 10,426,468, entitled HANDHELDELECTROMECHANICAL SURGICAL SYSTEM, and issued on Oct. 1, 2019, thedisclosure of which is herein incorporated by reference in its entirety.

The handle assembly 8520 includes an inner core 8522 and a disposableouter housing 8524 configured to selectively receive and encase innercore 8522 to establish a sterile barrier 8525 (FIG. 3 ) around the innercore 8522. Inner core 8522 is motor operable and configured to drive anoperation of a plurality of types of end effectors. Inner core 8522 hasa plurality of sets of operating parameters (e.g., speed of operation ofmotors of inner core 8522, an amount of power to be delivered by motorsof inner core 8522 to a shaft assembly, selection of motors of innercore 8522 to be actuated, functions of an end effector to be performedby inner core 8522, or the like). Each set of operating parameters ofinner core 8522 is designed to drive the actuation of a specific set offunctions unique to respective types of end effectors when an endeffector is coupled to inner core 8522. For example, inner core 8522 mayvary its power output, deactivate or activate certain buttons thereof,and/or actuate different motors thereof depending on the type of endeffector that is coupled to inner core 8522.

The inner core 8522 defines an inner housing cavity therein in which apower-pack 8526 is situated. Power-pack 8526 is configured to controlthe various operations of inner core 8522. Power-pack 8526 includes aplurality of motors operatively engaged thereto. The rotation of motorsfunction to drive shafts and/or gear components of shaft assembly 8530,for example, in order to drive the various operations of end effectorsattached thereto, for example, end effector 8540.

When end effector 8540 is coupled to inner core 8522, motors ofpower-pack 8526 are configured to drive shafts and/or gear components ofthe shaft assembly 8530 in order to selectively effect a firing motion,a closure motion, and/or an articulation motion at the end effector8540, for example.

Further to the above, the disposable outer housing 8524 includes twohousing portions 8524 a, 8524 b releasably attached to one another topermit assembly with the inner core 8522. In the illustrated example,the housing portion 8524 b is movably coupled to the housing portion8524 a by a hinge 8525 located along an upper edge of housing portion8524 b. Consequently, the housing portions 8524 a, 8524 b are pivotablerelative to one another between a closed, fully coupled configuration,as shown in FIG. 1 , and an open, partially detached configuration, asshown in FIG. 2 . When joined, the housing portions 8524 a, 8524 bdefine a cavity therein in which inner core 8522 may be selectivelysituated.

In the illustrated example, the inner core 8522 includes a controlcircuit 8560. In other examples, the control circuit 8560 is disposed onan inner wall of the disposable outer housing 8524, and is releasablycouplable to the inner core 8522 such that an electrical connection isestablished between the inner core 8522 and the control circuit 8560when the inner core 8522 is assembled with the outer housing 8524. Thecontrol circuit 8560 includes a processor 8562 and a storage medium suchas, for example, a memory unit 8564. The control circuit 8560 can bepowered by the power-pack 8526, for example. The memory unit 8564 maystore program instructions, which when executed by the processor 8562,may cause the processor 8562 to adjust/perform various control functionsof the surgical instrument system 8500.

In the illustrated example, the control circuit 8560 is releasablycouplable to the inner core 8522. When the inner core 8522 is assembledwith the outer housing 8524, an electrical connection is establishedbetween the inner core 8522 and the control circuit 8560. In otherexamples, however, the control circuit 8560 is incorporated into theinner core 8522.

In various examples, the memory unit 8564 may be non-volatile memories,such as, for example, electrically erasable programmable read-onlymemories. The memory unit 8564 may have stored therein discreteoperating parameters of inner core 8522 that correspond to the operationof one type of end effector, for example, end effectors such as, forexample end effector 8540 and/or one type of adapter assembly such as,for example, shaft assembly 8530. The operating parameter(s) stored inmemory 8564 can be at least one of: a speed of operation of motors ofinner core 8522; an amount of power to be delivered by motors of innercore 8522 during operation thereof; which motors of inner core 8522 areto be actuated upon operating inner core 8522; types of functions of endeffectors to be performed by inner core 8522; or the like.

Referring still to FIGS. 1-3 , the surgical instrument system 8500includes an electrical interface assembly 8570 configured to transmit atleast one of data signal and power between the inner core 8522 and theend effector 8540. In the illustrated example, the electrical interfaceassembly 8570 includes a first interface portion 8580 on a first side8525 a of the sterile barrier 8525 and a second interface portion 8590on a second side 8525 b of the sterile barrier 8525 opposite the firstside. In various aspects, the first interface portion 8580 is configuredto form a wireless electrical interface with the second interfaceportion 8590. The wireless electrical interface facilitates a wirelesstransmission of at least one of data signal and power between the innercore 8522 and the second interface portion 8590.

Furthermore, the electrical interface assembly 8570 includes anexteriorly-mounted wiring connection 8600. In the illustrated example,the exteriorly-mounted wiring connection 8600 is separately-attachableto the second interface portion 8690 to facilitate a wired transmissionof the at least one of data signal and power between the secondinterface portion 8590 and the end effector 8540.

In various aspects, the first interface portion 8580 and the secondinterface portion 8590 are configured to cooperatively form a wirelesssegment of an electrical pathway between the inner core 8522 and the endeffector 8540. In addition, the exteriorly-mounted wiring connection8600 forms a wired segment of the electrical pathway. At least one ofdata signal and power is transmitted between the inner core 8522 and theend effector 8540 through the electrical pathway.

Referring still to FIGS. 1-3 , the exteriorly-mounted wiring connection8600 includes a wire flex circuit 8601 terminating at an attachmentmember 8602 releasably couplable to the second interface portion 8590.The wire flex circuit 8601 is of sufficient length to permit theattachment member 8602 to exteriorly reach the second interface portion8590.

The attachment member 8602 is magnetically couplable to the secondinterface portion 8590. For example, the attachment member 8602 includesmagnetic elements 8606, 8608 disposed in the housing 8604. The firstinterface portion 8580 includes ferrous elements 8576, 8578 for magneticattachment and proper alignment of the attachment member 8602 onto theouter housing 8524, as illustrated in FIG. 3 .

The ferrous elements 8576, 8578 are disposed on an outer housing 8523 ofthe inner core 8522 such that the ferrous elements 8576, 8578 and themagnetic elements 8606, 8608 are aligned when the inner core 8522 isproperly positioned within the disposable outer housing 8524 and theattachment member 8602 is properly positioned against the secondinterface portion 8590.

Alternatively, in certain examples, magnetic elements can be disposed onthe outer housing 8523 of the inner core 8522, and the ferrous elementscan be disposed on the housing 8604 of the attachment member 8602.Alternatively, in certain examples, corresponding magnetic elements canbe disposed on both of the housings 8604, 8523.

Further to the above, another exteriorly-mounted wiring connection 8611connects the shaft assembly 8530 to the second interface portion 8590.The exteriorly-mounted wiring connection 8611 is similar in manyrespects to the exteriorly-mounted wiring connection 8600. For example,the exteriorly-mounted wiring connection 8611 also includes a wire flexcircuit 8612 that terminates in an attachment member 8613 that issimilar to the attachment member 8602 of the exteriorly-mounted wiringconnection 8600. The attachment member 8613 is alsomagnetically-couplable to the handle assembly 8520 to exteriorlytransmit at least one of data and power between the shaft assembly 8530and the inner core 8522.

Further to the above, the electrical interface assembly 8570 utilizesinductive elements 8603, 8583 positionable on opposite sides of thesterile barrier 8525. In the illustrated example, the inductive elements8603, 8583 are in the form of wound wire coils that are components ofinductive circuits 8605, 8585, respectively. The wire coils of theinductive elements 8603, 8583 comprise a copper, or copper alloy, wire;however, the wire coils may comprise suitable conductive material, suchas aluminum, for example. The wire coils can be wound around a centralaxis any suitable number of times.

When a proper magnetic attachment is established by the elements 8608,8606, 8576, 8578, as illustrated in FIG. 3 , the wire coils of theinductive elements 8603, 8583 are properly aligned about a central axisextending therethrough. The proper alignment of the wire coils of theinductive elements 8603, 8583 improves the wireless transmission of theat least one of data and power therethrough.

In various examples, the inductive circuit 8585 is electrically coupledto the power-pack 8526 and the control circuit 8560. In the illustratedexample, the inductive circuit 8605 is electrically couplable to atransponder 8541 in the end effector 8540. To transmit signals to thetransponder 8541 and receive signals therefrom, the inductive element8603 is inductively coupled to the inductive element 8583. Thetransponder 8541 may use a portion of the power of the inductive signalreceived from the inductive element 8603 to passively power thetransponder 8541. Once sufficiently powered by the inductive signals,the transponder 8541 may receive and transmit data to the controlcircuit 8560 in the handle assembly via the inductive coupling betweenthe inductive circuits 8605, 8585.

In various examples, as illustrated in FIG. 1 , the transponder 8541 islocated in the shaft portion 8542 of the end effector 8540. In otherexamples, the transponder 8541 can be disposed in the jaws of the endeffector 8540. In the illustrated example, the end effector 8540includes a staple cartridge 8543. In certain instances, the transponder8541 can be located in the staple cartridge 8543. Internal wiring withinthe shaft portion 8542 connects the exteriorly-mounted wiring connection8600 to the transponder 8541. In the illustrated example, theexteriorly-mounted wiring connection 8600 includes an attachment member8609 configured to connect the wire flex circuit 8601 to the shaftportion 8542. In certain instances, the attachment member 8609 ispermanently connected to the shaft portion 8542. In other instances, theattachment member 8609 is releasably coupled to the shaft portion 8542.

To transmit signals to the transponder 8541, the control circuit 8560may comprise an encoder for encoding the signals and a modulator formodulating the signals according to the modulation scheme. The controlcircuit 8560 may communicate with the transponder 8541 using anysuitable wireless communication protocol and any suitable frequency(e.g., an ISM band).

In various examples, the control circuit 8560 through queriesidentification devices (e.g., radio frequency identification devices(RFIDs)), or cryptographic identification devices, can determine whetheran attached staple cartridge and/or end effector is compatible with thesurgical instrument system 8500. An identification chip and/or aninterrogation cycle can be utilized to assess the compatibility of anattached staple cartridge and/or end effector. Various identificationtechniques are described in U.S. Pat. No. 8,627,995, entitledELECTRICALLY SELF-POWERED SURGICAL INSTRUMENT WITH CRYPTOGRAPHICIDENTIFICATION OF INTERCHANGEABLE PART, issued Jan. 14, 2014, which ishereby incorporated by reference herein in its entirety.

FIG. 4 is a logic flow diagram of a process 8610 depicting a controlprogram or a logic configuration electrically connecting an inner core8522 of a surgical instrument system (e.g. surgical instrument system8500) with a staple cartridge (e.g. staple cartridge 8543) or an endeffector (e.g. end effector 8540). The process 8610 includes detecting8612 a compatible connection between the end effector 8540 and the innercore 8522, more specifically the control circuit 8560, through theelectrical interface assembly 8570. The process 8610 further includesadjusting 8614 a signal parameter of a signal passing through theelectrical interface assembly 8570 to improve a throughput of the atleast one of data and power between the end effector 8540 and the innercore 8522.

In the illustrated example, the process 8610 is implemented by thecontrol circuit 8560. The memory unit 8564 may store programinstructions, which when executed by the processor 8562, may cause theprocessor 8562 to perform one or more aspects of the process 8610. Inother examples, one or more aspects of the process 8610 can beimplemented by a connection circuit separate from, but can be incommunication with, the control circuit 8560. The connection circuit canincorporated into the disposable outer housing 8524 of the handleassembly 8520, for example.

In various aspects, the end effector 8540 includes a memory unit thatstores an identification code. The control circuit 8560 may assesswhether a compatible connection exists between the end effector 8540 andthe inner core 8522 based on the identification code retrieved from thememory unit through the electrical interface assembly 8570.

In various aspects, the electrical interface assembly 8570 includes oneor more sensors configured to detect, measure, and/or monitor aspects ofthe signal transmitted through the electrical interface assembly 8570.The control circuit 8560 may further adjust one or more aspects of thesignal such as, for example, the signal strength, frequency, and/orbandwidth and/or adjust power levels to optimize the throughput of theat least one of data and power between the end effector 8540 and theinner core 8522 through the electrical interface assembly 8570. Invarious aspects, the control circuit 8560 can determine if the surgicalinstrument system 8500 is within an environment where one or morecomponents or connections of the electrical interface assembly 8570 areshorted and/or the signal is lost. In response, the control circuit 8560may adjust the signal frequency, signal strength, and/or signal repeatin order to improve data or power throughput. In at least one example,the control circuit 8560 may respond by turning off one or moreconnections in order to improve other connections of the electricalinterface assembly 8570.

Referring primarily to FIGS. 5 and 6 , the control circuit 8560 may setone or more operational parameter of the surgical instrument system 8500based on an identifier received through the electrical interfaceassembly 8570. FIG. 5 depicts a graph 8620 that represents severalcontrol schemes (e.g. 8621, 8622, 8623, 8624, 8625, 8626, 8627) that canbe stored in the memory unit 8564, and can be selected by the processor8562 based on the identifier received through the electrical interfaceassembly 8570. The graph 8620 includes an x-axis representing drivemember travel distance in millimeters (mm) and a y-axis representingdrive member speed in millimeters per second (mm/sec).

The drive member is motivated by the motor(s) of the inner core 8522 toeffect a closure and/or firing motion of the end effector 8540. In atleast one example, the drive member is motivated by the mortar toadvance an I-beam assembly along a predefined firing path to deploystaples from the staple cartridge 8543 into tissue and, optionally,advance a cutting member to cut the stapled tissue in a firing stroke.In such example, the drive member speed of motion and distance traveledfrom starting position represent the speed of motion of the I-beamassembly and the distance traveled by the I-beam assembly along thepredefined firing pathway, respectively.

The example control schemes (8621, 8622, 8623, 8624, 8625, 8626, 8627)represented in the graph 8620 can be stored in the memory unit 8564 inany suitable form such as, for example, tables and/or equations. Invarious aspects, the control schemes (8621, 8622, 8623, 8624, 8625,8626, 8627) represent different types and sizes (e.g. 45 mm, 60 mm) ofstaple cartridges suitable for use with the surgical instrument system8500 to treat different tissue types with different thicknesses. Forexample, the control scheme 8621 is for use with a cartridge typesuitable for treating thin tissue and, as such, permits relativelyfaster speeds of motion of the drive member, which yields a higherinertia, which necessitates an earlier slowdown before the end of thefiring stroke. Contrarily, the control scheme 8627 is for use with acartridge type suitable for treating thick tissue and, as such, permitsslower speeds of motion of the drive member than the control scheme8621. Accordingly, the control scheme 8627 yields a lower inertia thanthe control scheme 8621, which justifies a later slowdown before the endof the firing stroke compared to the control scheme 8621.

FIG. 6 depicts another graph 8720 representing additional controlschemes (8721, 8722, 8723, 8724). The graph 8720 illustrates drivemember speed on the x-axis and motor current (i) on the y-axis fordifferent cartridge types suitable for different tissuetypes/thicknesses. The current draw of the motor of the inner core 8522to achieve a particular speed of the drive member varies depending onthe cartridge type. Accordingly, the control circuit 8560 selects fromthe control schemes (8721, 8722, 8723, 8724) based on the identifierreceived through the electrical interface assembly 8570 to ensure acurrent draw by the motor sufficient to achieve a desired speed asdetermined by the selected control scheme.

Referring now to FIG. 7 , a surgical instrument system 8800 is similarin many respects to the surgical instrument system 8500. For example,the surgical instrument system 8800 also includes a handle assembly 8820that includes an inner core 8822 which has a motor assembly formotivating a drive member configured to effect a closure motion and/or afiring motion in an end effector 8540. The inner core 8822 furtherincludes an internal power pack 8826 that powers the motor assembly anda control circuit 8860. In various aspects, the power pack 8826comprises one or more batteries, which can be rechargeable. In certainaspects, the power pack 8826 can be releasably couplable to the innercore 8822.

Similar to the control circuit 8560, the control circuit 8860 includes amemory unit that stores program instructions. The program instructions,when executed by the processor, cause the processor to control the motorassembly, a feedback system, and/or one or more sensors. In variousexamples, the feedback system can be employed by the control circuit8860 to perform a predetermined function such as, for example, issuingan alert when one or more predetermined conditions are met. In certaininstances, the feedback systems may comprise one or more visual feedbacksystems such as display screens, backlights, and/or LEDs, for example.In certain instances, the feedback systems may comprise one or moreaudio feedback systems such as speakers and/or buzzers, for example. Incertain instances, the feedback systems may comprise one or more hapticfeedback systems, for example. In certain instances, the feedbacksystems may comprise combinations of visual, audio, and/or hapticfeedback systems, for example.

Still referring to FIG. 7 , a wireless power transfer system 8850 isutilized to wirelessly transmit power across a sterile barrier createdby a disposable outer housing 8824 disposed around the inner core 8822.The disposable outer housing 8824 is similar in many respects to thedisposable outer housing 8524. For example, the disposable outer housing8824 may include two housing portions detachably couplable to oneanother to permit insertion of the inner core 8822 inside the disposableouter housing 8824. The inner core 8822 is sealed inside the disposableouter housing 8824, thereby creating the sterile barrier around theinner core 8822.

The wireless power transfer system 8850 utilizes magnetic coupling ofbearings to drive mechanical work to ultimately be converted to usableelectrical energy. The wireless power transfer system 8850 includes aninternal power transfer unit 8852 and an external disposable energyreceiver/converter 8854. In the illustrated example, the internal powertransfer unit 8852 and the external disposable energy receiver/converter8854 are positioned on opposite sides of the sterile barrier defined bythe disposable outer housing 8824.

The internal power transfer unit 8852 is positioned inside thedisposable outer housing 8824, and is hardwired to the power pack 8826.In one example, the internal power transfer unit 8852 is attached to aninner wall of the disposable outer housing 8824, and is releasablyconnected to the power pack 8826. When the inner core 8822 is properlypositioned within the disposable outer housing 8824, an externalconnector thereof is brought into a mating engagement with acorresponding connector of the internal power transfer unit 8852. Whenthe connectors are engaged, the power pack 8826 and the internal powertransfer unit 8852 become electrically connected. In other examples,however, the inner core 8822 may include an external wiring that can bemanually connected to the internal power transfer unit 8852.

In other examples, the internal power transfer unit 8852 is incorporatedinto the inner core 8822. In such examples, the internal power transferunit 8852 is positioned near an external housing of the inner core 8822in such a manner that brings the internal power transfer unit 8852 intoa proper operational alignment with the external disposable energyreceiver/converter 8854 when the inner core 8822 is finally positionedwithin the disposable outer housing 8824.

Further to the above, the internal power transfer unit 8852 includes amagnetic bearing 8856. The control circuit 8860 causes a current todrive the rotation of the magnetic bearing 8856. The mechanical energyis magnetically transmitted across the sterile barrier to the externaldisposable energy receiver/converter 8854, and is converted again toelectrical energy via a linear alternator 8857. The external disposableenergy receiver/converter 8854 includes a magnetic bearing 8858configured to rotate with rotation of the magnetic bearing 8856. Inoperation, the magnetic bearing 8858 is synchronized to the rotation ofthe magnetic bearing 8856, which causes mechanical work to be generatedexternally in an outer power transfer unit 8854. The generatedmechanical work is harnessed and converted to electrical energy via thelinear alternator 8857 and is then available for utilization with an endeffector 8540, for example. In various aspects, a gear assembly 8859 isutilized to transfer the mechanical energy from the magnetic bearing8858 to the linear alternator 8857.

In various instances, power transfer across the sterile barrier can beachieved via a direct conductive connection is between the internal andexternal environments. A specific region of the outer disposable housingcan be over-molded onto a metal strip that extends the thickness of thesterile barrier when implemented. The over-molding will allow for tightseals to remove the chance of contaminants getting through, and once theouter housing is transitioned to a closed configuration to create thesterile barrier, the metal strip will act as a conductive bridgeallowing energy to be transferred directly to the external environment.

Referring now to FIGS. 8 and 9 , a surgical instrument system 8900 issimilar in many respects to the surgical instrument systems 8500, 8800.For example, the surgical instrument system 8900 also includes a handleassembly 8920 that includes an inner core 8922 which has a motorassembly for motivating a drive member configured to effect a closuremotion and/or a firing motion in an end effector 8940.

In addition, the surgical instrument system 8900 includes a shaft 8930with a nozzle portion 8930 a and a shaft portion 8930 b extendingdistally from the nozzle portion 8930 a. The nozzle portion 8930 apermits rotation of the end effector 8940 relative to the handleassembly 8920. A flex circuit 8934 is configured to transmit power tothe end effector 8940 through the nozzle portion 8930 a. The flexcircuit 8934 comprises a proximal flex circuit segment 8934 a disposedon the handle assembly 8920 and a distal flex circuit segment 8934 cdisposed on the shaft portion 8930 b and the end effector 8940.

In addition, the flex circuit 8934 includes a conductive metal segment8934 b frictionally connected to the proximal flex circuit segment 8934a and fixedly connected to the distal flex circuit segment 8934 c. Theconductive metal segment 8934 b facilitates rotation of the shaft 8930and the end effector 8940 relative to the handle assembly 8920 whilemaintaining an electrical connection between the handle assembly 8920and the end effector 8940. In the illustrated example, the conductivemetal segment 8934 b includes a conductive ring 8935 frictionallyattached to the proximal flex circuit segment 8934 a.

Further to the above, the flex circuit 8934 is configured to transmitpower from an external power source 8926 to the end effector 8940. Theexternal power source 8926 is disposed onto the disposable outer housing8924. A connection between the external power source 8926 and the flexcircuit 8934 can be protected from surrounding environment by beingpartially, or fully, embedded in the disposable outer housing 8924, forexample. In the illustrated example, the external power source 8926includes a connection port 8927 configured to receive a proximal end ofthe proximal flex circuit segment 8934 a.

Additionally, the inner core 8922 may include an internal power packthat powers the motor assembly and a control circuit. In variousaspects, the power pack electrically coupled to the flex circuit 8934and/or the external power source 8926 by an electrical interfaceassembly 8570 in a similar manner to that described in connection withthe surgical instrument system 8500. In certain examples, the externalpower source 8926 is fully replaced by the internal power pack of theinner core 8922. In such examples, power is transmitted to the flexcircuit 8934 from the internal power pack through the sterile barriervia the electrical interface assembly 8570.

Further to the above, the flex circuit 8934 may also include an endeffector segment 8934 d configured to connect the distal flex circuitsegment 8934 c to a staple cartridge 8944 releasably coupled to the endeffector 8940. The end effector segment 8930 d comprises sufficientslack to prevent over extension of the end effector segment 8930 d,which can be caused by end effector motions.

Referring now to FIG. 10 , a surgical instrument system 9000 is similarin many respects to the surgical instrument system 8500. For example,the surgical instrument system 9000 also includes a handle assembly 9020that includes an inner core 9022 which has a motor assembly formotivating a drive member configured to effect a closure motion and/or afiring motion in an end effector (e.g. end effector 8540). A disposableouter housing 9024 defines a sterile barrier 9025 around the inner core9022.

The handle assembly 9020 further includes an electrical interfaceassembly 9070 configured to transmit at least one of data signal andpower between the inner core 8922 and the end effector 8540 through thesterile barrier 9025 defined by the disposable outer housing 9024. Theelectrical interface assembly 9070 includes an internal piezoelectrictransducer 9071 coupled to an internal power pack 9026 configured toenergize the internal piezoelectric transducer 9071. The electricalinterface assembly 9070 further includes a lens coupled to the internalpiezoelectric transducer 9071, and configured to focus ultrasound energygenerated by the internal piezoelectric transducer 9071 through agel-like membrane 9072 into an external piezoelectric transducer 9073.Accordingly, electrical energy provided by the power pack 9026 isconverted into ultrasound energy that is transmitted across the sterilebarrier 9025 to be received by the external piezoelectric transducer9073. The ultrasound energy is then transferred to electrical energy bythe external piezoelectric transducer 9073. In certain instances, a flexcircuit further transmits the electrical energy to an end effector, forexample.

FIG. 11 depicts a modular surgical instrument system 9100 similar inmany respects to the surgical instrument system 8500. For example, themodular surgical instrument system 9100 also includes a handle assembly9120, a shaft 9130, and a loading unit 9140 including a proximal shaftportion 9140 a and an end effector 9140 b. The loading unit 9140 isreleasably connectable to a distal shaft portion 9130 b of the shaft9130. A nozzle portion 9130 a of the shaft 9130 is also releasablyconnectable to the handle assembly 9120. Furthermore, a staple cartridge9144 is releasably connectable to the end effector 9140 b. In otherinstances, the staple cartridge is integrated with the end effector 9140b.

Like the handle assembly 8520, the handle assembly 9120 includes aninner core 9122 and a disposable outer housing 9124 configured toselectively receive and encase the inner core 9122 to establish asterile barrier 9125 around the inner core 9122. Inner core 9122 ismotor operable and configured to drive an operation of a plurality oftypes of end effectors. Inner core 9122 has a plurality of sets ofoperating parameters (e.g., speed of operation of motors of inner core9122, an amount of power to be delivered by motors of inner core 9122 toa shaft assembly, selection of motors of inner core 9122 to be actuated,functions of an end effector to be performed by inner core 9122, or thelike). Each set of operating parameters of inner core 9122 is designedto drive the actuation of a specific set of functions unique torespective types of end effectors when an end effector is coupled toinner core 9122. For example, inner core 9122 may vary its power output,deactivate or activate certain buttons thereof, and/or actuate differentmotors thereof depending on the type of end effector that is coupled toinner core 9122.

The inner core 9122 defines an inner housing cavity that accommodates apower pack and one or more motors powered by the power pack. Therotation of motors function to drive shafts and/or gear components ofthe shaft 9130, for example, in order to drive the various operations ofend effectors attached thereto, for example, end effector 9140.

Further to the above, the outer housing 9124 includes two housingportions 9124 a, 9124 b releasably attached to one another to permitassembly with the inner core 9122. In the illustrated example, thehousing portion 9124 b is movably coupled to the housing portion 9124 aby a hinge located along an upper edge of the housing portion 9124 b.Consequently, the housing portions 9124 a, 9124 b are pivotable relativeto one another between a closed, fully coupled configuration, as shownin FIG. 11 , and an open, partially detached configuration. When joined,the housing portions 9124 a, 9124 b define a cavity therein in whichinner core 9122 may be selectively situated.

Similar to the control circuit 8560, the control circuit 9160 includes amemory unit that stores program instructions. The program instructions,when executed by a processor, cause the processor to control the motorassembly, a feedback system, and/or one or more sensors, for example. Invarious examples, the feedback system can be employed by the controlcircuit 9160 to perform a predetermined function such as, for example,issuing an alert when one or more predetermined conditions are met. Incertain instances, the feedback systems may comprise one or more visualfeedback systems or a visual interface such as display screens,backlights, and/or LEDs, for example. In certain instances, the feedbacksystems may comprise one or more audio feedback systems such as speakersand/or buzzers, for example. In certain instances, the feedback systemsmay comprise one or more haptic feedback systems, for example. Incertain instances, the feedback systems may comprise combinations ofvisual, audio, and/or haptic feedback systems, for example.

In various aspects, one or more sensors can be configured to detect ormeasure whether the disposable outer housing 9124 in an openconfiguration or a closed configuration. In the illustrated example, aHall Effect sensor 9123 detects a transition of the housing portion 9124a, 9124 b to a closed configuration or to an open configuration. Thecontrol circuit 9160 may receive an input signal indicative of whetherthe disposable outer housing 9124 is in the open configuration or closedconfiguration. In certain examples, other suitable sensors can beemployed to detect the closed configuration and/or the openconfiguration such as, for example, other magnetic sensors, pressuresensors, inductive sensors, and/or optical sensor.

Referring still to FIG. 11 , the modular surgical instrument system 9100includes an electrical interface assembly 9170 configured to transmit atleast one of data signal and power across the sterile barrier 9125,outside the sterile barrier 9125, and/or within the sterile barrier9125. The at least one of data signal and power is transmitted betweenone or more of the modular components of the modular surgical instrumentsystem 9100. In the illustrated example, the electrical interfaceassembly 9170 includes a first interface portion 9180 on a first side(inside the disposable outer housing 9124) of the sterile barrier 9125and a second interface portion 9190 on a second side (outside thedisposable outer housing 9124) of the sterile barrier 9125 opposite thefirst side.

Furthermore, the electrical interface assembly 9170 includes a wiringassembly 9171 that includes exteriorly-mounted wiring connections 9101,9102, 9103 that electrically couple the second interface portion 9190 tothe loading unit 9140, a loading unit-to-shaft connection sensor 9141,and the nozzle portion 9130 a, respectively, and correspondinginternally-mounted wiring connections 9101′, 9102′, 9103′ that couplethe first interface portion 9180 to the control circuit 9160. The wiringconnections 9101, 9102, 9103, 9101′, 9102′, 9103′ cooperate with theinterface portions 9180, 9190 to transmit signals between the controlcircuit 9160 and the loading unit 9140, the staple cartridge 9144, theloading unit-to-shaft connection sensor 9141, and the nozzle portion9130 a, as discussed in greater detail below. In certain instances, abuttress is attached to the staple cartridge 9144. In such instances,the wiring connections 9101, 9101′ may facilitation the transmission ofsignals between the control circuit 9160 and a buttress-attachmentsensor configured to detect a buttress unique identifier, for example,as discussed in greater detail below.

In addition, the wiring assembly 9171 further includesinternally-mounted wiring connections 9104, 9105, 9106, 9107 configuredto electrically couple the control circuit 9160 to a handleassembly-to-shaft connection sensor 9131, the first housing portion 9124a, the second housing portion, and an inner core-to-handle assemblyconnection sensor 9121. In at least one example, one or more of thewiring connections of the wiring assembly 9161 comprise connector endsreleasably couplable to corresponding connector ends of correspondingmodular components of the modular surgical instrument system 9100.

In certain examples, the handle assembly 9120 may include an electricalinterface assembly that facilitates a wired connection through thesterile barrier 9125. Wire portions may be passed through the disposableouter housing 9124. For example, the wire portions can be partiallyembedded in a handle assembly outer wall. Suitable insulation can beprovided to prevent fluid leakage.

Referring to FIG. 12 , various possible modular components of themodular surgical instrument system 9100 are listed along with uniqueidentifier resistances for each of the listed modular components. Thelisted modular components may facilitate surgical stapling, surgicalultrasonic energy treatment, surgical radio-frequency (RF) energytreatment, and various combinations thereof.

The modular components include various types of inner cores, handleassemblies, shafts, loading units, staple cartridges with differenttypes and sizes, and/or buttress attachments with different shapes andsizes, which can be assembled in various combinations to form a modularsurgical instrument system 9100. Since each modular component comprisesa unique identifier resistance, a total sensed resistance can bedetermined to identify a connected modular configuration based on theunique identifier resistances of its modular components.

In certain aspects, the control circuit 9160 may compare an expectedvalue of the total sensed resistance to a measured value of the totalsensed resistance to verify, or confirm, the identity of the modularcomponents in a modular configuration. In at least one example, thecontrol circuit 9160 may receive user input identifying components ofmodular configuration through a user interface, for example.Additionally, or alternatively, the control circuit 9160 may directlycompare expected values of the identifier resistances to correspondingmeasured values of the identifier resistances to verify, or confirm, theidentity of the modular components in a modular configuration, forexample.

In other aspects, the control circuit 9160 may compare an expected valueof the total sensed resistance to a measured value of the total sensedresistance to assess or detect irregularities in connected modularcomponents of a modular configuration. Additionally, or alternatively,the control circuit 9160 may compare expected values to measured valuesfor each of the modular components to assess or detect irregularities inthe connected modular components of a modular configuration.

In the illustrated example, a graph 9161 illustrates expected andmeasured, or detected, identifier resistance values. Based on acomparison of the expected and measured, or detected, resistantidentifier values the control circuit 9160 determines that an innercore, a disposable outer housing, a shaft, an end effector, a cartridge,and a buttress with unique identifier resistances R_(1a), R_(2a),R_(3d), R_(4c), R_(5b), R_(6c), respectively, are connected in a modularconfiguration.

In the illustrated examples, lines 9163, 9164 illustrate scenarios wherean outer housing and a buttress, respectively, are either not connectedor are not authentic. Additionally, lines 9165, 9166 illustratescenarios where an outer housing and a buttress, respectively, areconnected, but are not authentic. In such complex configurations,checking authenticity of the modular components ensures that the modularconfiguration will work properly

A deviation between the expected and measured, or detected, resistantidentifier values may indicate a not-connected status, a not-authenticstatus, or other irregularities. The amount of deviation dictateswhether the control circuit 9160 determines a not-connected status, anot-authentic status, or a connected authentic status. In certainexamples, the control circuit 9160 may calculate the deviation amountand compare the calculated deviation amount to a predetermined thresholdto assess whether the deviation represents a not-connected status, anot-authentic status, or an authentic/connected status.

In certain examples, a deviation magnitude selected from a range ofgreater than 0% to about 10%, a range of greater than 0% to about 20%, arange of greater than 0% to about 30%, a range of greater than 0% toabout 40%, or a range of greater than 0% to about 50% indicates anot-authentic status. In certain examples, a deviation indicative of anot-authentic status is less than a deviation indicative of anot-connected status.

FIG. 13 is a logic flow diagram of a process 9150, depicting a controlprogram or a logic configuration for detecting and/or authenticating amodular configuration of a modular surgical instrument system orassembly. One or more aspects of the process 9150 can be performed by acontrol circuit such as, for example, the control circuit 9160 of themodular surgical instruments system 9100. In various aspects, theprocess 9150 includes generating 9152 an interrogation signal to detect,or confirm identity, of modular components of an assembled modularconfiguration of a modular surgical instruments system 9100. In theevent, the identities of the modular components are to be confirmed, theidentities could be supplied through a user interface coupled to thecontrol circuit 9160, for example.

In any event, the interrogation signal can be transmitted to the modularcomponents of the modular configuration through the wiring assembly 9171and/or electrical interface assembly 9170. The interrogation signal maytrigger a response signal from the modular components of the modularconfiguration. The response signal can be detected 9153 and utilized bythe control circuit 9160 to detect 9154, or confirm, identity of themodular components in the modular configuration.

As described above in greater detail, each of the modular componentsavailable for use with the modular surgical instrument system 9100includes an identifier resistance unique to the modular component.Accordingly, the control circuit 9160 may utilize the response signal tocalculate the identifier resistances of the modular components of themodular configuration. The identities of the modular components of themodular configuration can then be detected 9154, or confirmed, based onthe calculated identifier resistances. Confirmation of the identities ofthe modular components of the modular configuration can be achieved bythe control circuit 9160 by comparing the identities entered through theuser interface with the identities detected based on the responsesignal.

In certain aspects, the control circuit 9160 causes a current to passthrough the wiring assembly 9171 and the electrical interface assembly9170 to the modular components of the modular configuration. The returncurrent can then be sampled to calculate a total sensed resistance ofthe modular configuration. Since each of the individual modularcomponents has a unique identifier resistance, the control circuit 9160can determine the identities of the individual modular components basedon the total sensed resistance of the modular configuration.

In certain aspects, the control circuit 9160 compares an expected valueof the total sensed resistance to a determined value of the total sensedresistance to confirm a proper assembly of a modular configuration. Inat least one form, the expected value is stored in a memory unit, whichis accessed by the control circuit 9160 to perform the comparison.

A deviation between the expected value and the determined value with amagnitude equal to, or at least substantially equal to, the resistanceidentifier of one or more modular components causes the control circuit9160 to conclude that the one or more modular components are notconnected in the modular configuration. In response, the control circuit9160 may assign a not-connected status. The control circuit 9160 mayalso issue an alert 9151 regarding the one or more modular componentsthrough the user interface. The control circuit 9160 may further provideinstructions for how to properly connect the deemed-unconnected modularcomponents.

In certain instances, the process 9150 may further include assessing9155 authenticity of the modular configuration based on the responsesignal. In at least one example, the control circuit 9160 assesses theauthenticity of the modular configuration based on a comparison betweenexpected and determined values of the unique identifier resistances ofthe modular components. The control circuit 9160 may compare themagnitude of a detected deviation between expected and determined valuesof a unique identifier resistance to a predetermined threshold to assess9155 authenticity of a detected modular component in a modularconfiguration.

In at least one example, the predetermined threshold is a thresholdrange. If the magnitude of the detected deviation is beyond, thepredetermined threshold, the control circuit 9160 may select a suitablesecurity response 9156 such as, for example, assigning a non-authenticstatus to the modular component, issuing an alert through the userinterface, and/or temporarily deactivating the surgical instrumentsystem 9100. In various aspects, the threshold range is about ±1%, about±2%, about ±3%, about ±4%, about ±5%, about ±10%, or about ±20% from theexpected value, for example. Other ranges are contemplated by thepresent disclosure.

FIG. 14 is a logic flow diagram of a process 9110, depicting a controlprogram or a logic configuration for detecting and/or authenticating amodular configuration of a modular surgical instrument system orassembly. One or more aspects of the process 9110 can be performed by acontrol circuit such as, for example, the control circuit 9160 of themodular surgical instruments system 9100. In various aspects, theprocess 9110 includes detecting 9111 an identification signal of anassembled modular configuration of the modular surgical instrumentsystem 9100. In certain examples, the identification signal is acombined response signal transmitted by modular components of themodular configuration in response to an interrogation signal generatedby the control circuit 9160.

Furthermore, the control circuit 9160 may assess authenticity of themodular components of the modular configuration. If 9112 theidentification signal is detected, the control circuit 9160 measures9113 a characteristic of the modular configuration, determines 9114 anauthentication key based on at least one measurement of thecharacteristic, and authenticates 9115 the identification signal basedon the authentication key. If 9116 the control circuit 9160 determinesthat the modular configuration is not authentic, the control circuit9160 may further generate a security response, as described inconnection with the process 9150.

In various aspects, the control circuit 9160 is configured to determinethe authentication key independently of the identification signal. Theauthentication key can be based on a characteristic common amongindividual modular components of the modular configuration. In at leastone example, the common characteristic can be an environmentalcharacteristic. In certain examples, the common characteristic can be alocation, a radio-frequency (RF) intensity, a sound level, a lightlevel, and/or a magnetic field strength.

In various aspects, a modular component of the modular configurationmeasures the common characteristic, and generates the authentication keybased on at least one measurement of the common characteristic. Themodular component may further encode an identification signal based onthe generated authentication key, and transmits the encodedidentification signal to the control circuit 9160 through the wiringassembly 9171 and/or the electrical interface assembly 9170. The controlcircuit 9160 may independently measure the common characteristic, anddetermine the authentication key based on at least one measurement ofthe common characteristic. The control circuit 9160 may further utilizethe authentication key to authenticate and/or decode the identificationsignal received from the modular component.

In certain examples, the handle assembly 9120 generates a magnetic fieldwith a strength measureable by each of the modular components in amodular configuration. The modular components can utilize the measuredmagnetic field strength to encode identification signals transmitted tothe control circuit 9160 through the wiring assembly 9171 and/or theelectrical interface assembly 9170. In addition, the control circuit9160 separately determines the strength of the magnetic field. Incertain instances, the control circuit 9160 sets the strength of themagnetic field. In other instances, the control circuit 9160 measuresthe strength in a similar manner to modular components.

The control circuit 9160 decodes the encoded identification signalsbased on an authentication key generated from one or more measurementsof the strength of the magnetic field. Measuring the magnetic field canbe accomplished by one or more sensors such as, for example, amagnetometer. In other instances, the common characteristic is aradio-frequency (RF) intensity, a sound level, or a light level, thecontrol circuit 9160 employs an RF intensity sensor, an auditory sensor,or a photoelectric sensor, respectively, to measure the commoncharacteristic.

FIG. 15 illustrates a handle assembly 9220 of a modular surgicalinstrument 9200 similar in many respects to the modular surgicalinstruments 8500, 9100, which are not repeated herein in the same levelof detail for brevity. For example, the handle assembly 9220 includes aninner core 9222 and a disposable outer housing 9224 configured toselectively receive and encase inner core 9222 to establish a sterilebarrier 9225 around the inner core 9222. Inner core 9222 is motoroperable and configured to drive an operation of a plurality of types ofend effectors. Inner core 9222 has a plurality of sets of operatingparameters (e.g., speed of operation of motors of inner core 9222, anamount of power to be delivered by motors of inner core 9222 to a shaftassembly, selection of motors of inner core 9222 to be actuated,functions of an end effector to be performed by inner core 9222, or thelike). Each set of operating parameters of inner core 9222 is designedto drive the actuation of a specific set of functions unique torespective types of end effectors when an end effector is operablycoupled to inner core 9222. For example, inner core 9222 may vary itspower output, deactivate or activate certain buttons thereof, and/oractuate different motors thereof depending on the type of end effectorthat is operably coupled to inner core 9222.

Further to the above, the outer housing 9224 includes two housingportions 9224 a, 9224 b releasably attached to one another to permitassembly with the inner core 9222. In the illustrated example, thehousing portions 9224 a, 9224 b are movable relative to one anotherbetween a closed, fully coupled configuration, and an open, partiallydetached, or fully detached, configuration. When joined, the housingportions 9224 a, 9224 b define a cavity therein in which inner core 9222may be selectively situated.

Furthermore, the handle assembly 9220 includes a primary interfaceassembly 9270 configured to transmit at least one of data and powerbetween the inner core 9222 and at least one of modular components ofthe modular surgical instrument system 9200. The primary interfaceassembly 9270 includes a first interface portion 9270 a disposed ontothe inner core 9222 and a second interface portion 9270 b disposed on aninner wall of the disposable outer housing 9224. The interface portions9270 a, 9270 b include corresponding electrical contacts that becomeelectrically connected, or form an electrical connection, when the innercore 9222 is properly assembled with the disposable outer housing 9224.In various aspects, the primary interface assembly 9270 facilitates anelectrical connection between a power pack 9226 of the inner core 9222and an external charging system. The primary interface assembly 9270also facilitates the detection of a modular configuration of the modularsurgical instrument system 9200 by transmitting at least one of powerand data therethrough between the inner core 9222 and the modularconfiguration. In at least one example, the electrical contacts comprisespring contacts such as, for example, leaf-spring contacts.

In various aspects, the handle assembly 9220 includes a secondaryinterface 9262 including one or more sensors 9261 configured to detectthe presence of the inner core 9222 in the disposable outer housing9224. The control circuit 9260 is configured to confirm a primaryconnection through the primary interface assembly 9270 based on at leastone reading of the sensor 9261. Position and/or sensitivity of a sensor9261 can be set to detect the inner core 9222 when the inner core 9222is in the right position and alignment within the disposable outerhousing to establish a wired connection between the interface portions9270 a, 9270 b. In certain instances, readings from the sensor 9261 mustbe greater than, or equal, to a predetermined threshold to cause thecontrol circuit 9260 to detect that the inner core 9222 is correctlyinserted into the disposable outer housing 9224. The control circuit9260 may continuously compare readings of the sensor 9261 to thepredetermined threshold to determine whether the inner core 9222 iscorrectly inserted into the disposable outer housing 9224.

In various aspects, the sensor 9261 comprises a proximity sensor suchas, for example, a magnetic sensor, such as a Hall Effect sensor, aninductive sensor, such as an eddy current sensor, a resistive sensor, acapacitive sensor, an optical sensor, and/or any other suitable sensor.In certain examples, the control circuit 9260 is configured toidentify/detect an inner core 9222 through the secondary interface 9262based on a unique identifier 9263 of the inner core 9222 such as, forexample, a QR code, a resistance identifier, a voltage identifier,and/or a capacitance identifier.

Referring still to FIG. 15 , the control circuit 9260 is furtherconfigured to detect a closed configuration of the disposable outerhousing 9224 of the handle assembly 9220. The control circuit 9260 maydetect the closed configuration based on at least one reading of atleast one sensor 9264 within the disposable outer housing 9224. In atleast one example, the sensor 9264 is a proximity sensor. In theillustrated example, the sensor 9264 is a Hall Effect sensor. In otherinstances, the sensor 9264 can be an inductive sensor, such as an eddycurrent sensor, a resistive sensor, a capacitive sensor, an opticalsensor, and/or any other suitable sensor.

Additionally, or alternatively, the control circuit 9260 may detect theclosed configuration when an input signal is received from aclosed-configuration detection circuit 9265. Electrical contacts of theclosed-configuration detection circuit 9265 are disposed on the housingportions 9224 a, 9224 b such that the closed-configuration detectioncircuit 9265 becomes a closed-circuit when the disposable outer housing9224 is in the closed configuration. The transition to theclosed-circuit causes an electrical signal to be transmitted to thecontrol circuit 9260, which causes the control circuit 9260 todetect/confirm the closed configuration.

Referring to FIG. 16 , a graph 9280 is depicted. Distance (δ) betweenthe housing portions 9224 a, 9224 b is illustrated on the X-axis, andcapacitance measured from the inner core 9222 to the disposable outerhousing 9224 is depicted on the Y-axis. In various aspects, the controlcircuit 9260 is configured to assess a proper assembly of the inner core9222 with the disposable outer housing 9224 based on the distancebetween the housing portions 9224 a, 9224 b, and based on capacitancemeasured from the inner core 9222 to the disposable outer housing 9224.Alternatively, the control circuit 9260 can be configured to assess theproper assembly of the inner core 9222 with the disposable outer housing9224 based on the distance between the inner core 9222 and thedisposable outer housing 9224, and based on capacitance measured fromthe inner core 9222 to the disposable outer housing 9224.

In various aspects, a proper assembly of the inner core 9222 with thedisposable outer housing 9224 is detected by the control circuit 9260when two conditions are met, as represented by curved line 9281 of graph9280. The first condition is that a detected distance (δ) between afirst datum on the first housing-portion 9224 a and a correspondingsecond datum on the second housing-portion 9224 b is less than or equalto a predetermined threshold distance. The second condition is that adetected value of the capacitance measured from the inner core 9222 tothe disposable outer housing 9224 is within a predetermined capacitancerange (μF_(min)−μF_(max)).

In the illustrated example, curved line 9281 represents a properlyassembled handle assembly 9220, wherein the inner core 9222 is properlypositioned within the disposable outer housing 9224, and wherein thehousing portions 9224 a, 9224 b are properly sealed in the closedconfiguration. Conversely, curve lines 9282, 9283, 9284 representimproperly assembled handle assemblies 9220. The curve line 9282indicates that a closed configuration has not been achieved, and thecurve line 9283 indicates that the inner core 9222 is not properlypositioned with thin the disposable outer housing 9224.

Capacitance can also be indicative of authenticity of the inner core9222 and/or the disposable outer housing 9224. In the illustratedexample, the predetermined capacitance range (μF_(min)−μF_(max)) alsorepresents a capacitance-based authentication range. For example, curvedlines 9281, 9282 of graph 9280 represent an authentic inner core 9222and/or disposable outer housing 9224, while the curved line 9283 on thegraph 9280 illustrates non-authentic inner core 9222 and/or disposableouter housing 9224. Additionally, the curved line 9284 indicates theabsence of a capacitive identifier from the inner core 9222.

Referring now to FIGS. 17-20 , a surgical instrument system 9300 issimilar in many respects to other surgical instrument systems describedelsewhere herein such as, for example, the surgical instrument systems8500, 9100, 9200, which are not repeated herein at the same level ofdetail for brevity. For example, the surgical instrument system 9300includes a handle assembly 9320, a shaft assembly 9330, and a loadingunit including an end effector 9340 that releasably accommodates astaple cartridge 9341. The handle assembly 9320 includes a disposableouter housing 9324 configured to define a sterile barrier 9325. An innercore is positionable within the disposable outer housing 9324. The innercore is configured to drive and/or control various functions of thesurgical instrument system 9300, as described elsewhere herein withrespect to other similar inner cores.

Further to the above, the surgical instrument system 9300 includes anexternal power source 9326. In the illustrated example, the externalpower source 9326 is disposed on to an outer wall of the disposableouter housing 9324. In other examples, the external power source 9326can be integrated into the disposable outer housing 9324. An electricalinterface assembly 9328 is configured to transmit at least one of dataand power from the handle assembly 9320 to the end effector 9340. In theillustrated example, the electrical interface assembly 9328 includes aflex circuit 9327 extending between, and coupled to, the external powersource 9326 and a data communication band 9332 disposed in a nozzleportion 9331 of the shaft assembly 9330. In the illustrated example, thedata communication band 9332 comprises an annular shape that permitsrotation of the nozzle portion 9331 and other portions of the shaftassembly 9330 without wire entanglement.

Furthermore, the shaft assembly 9330 includes concentric conductiverings 9337, 9338 that facilitate a transmission of the at least one ofpower and data therebetween without hindering notation of the shaftassembly 9330. The conductive ring 9337 is disposed on an outer surfaceof an inner portion 9335, and the conductive ring is disposed on aninner annular surface of an outer portion 9336. In the illustratedexample, the inner portion 9335 is concentric with the outer portion9336.

FIG. 21 is a logic flow diagram of a process 9350 depicting a controlprogram or a logic configuration for disabling an inner core of a handleassembly of a surgical instrument system at an end-of-life event. Usingthe inner core beyond its lifecycle poses a serious risk to the patient.Various circuits and other features of the inner core are carefullydesigned to ensure a safe operation of the inner core within itslifecycle. Beyond the predetermined lifecycle, however, the inner coremay not function properly which, in many events, is not discovered untilthe handle assembly is actually used in surgery.

In various aspects, the process 9350 can be performed by the handleassembly 9220 of the surgical instrument system 9200, for example. Theprocess 9350 detects 9351 a proper assembly of the inner core 9222 withthe disposable outer housing 9224. A control circuit performing one ormore aspects of the process 9350 can be configured to detect the properassembly based on at least one reading of at least one sensor within theouter housing 9224. In at least one example, one or more aspects of theprocess 9350 can be performed by the control circuit 9260 (FIG. 15 ). Asdiscussed elsewhere herein in greater detail, the control circuit 9260can be configured to detect a proper assembly of the inner core 9222with the disposable outer housing 9224 based on readings from thesensors 9261, 9264, for example.

In any event, if 9352 a proper assembly is detected, a usage count ofthe inner core 9222 is increased 9353 by one. In at least one example,the control circuit 9260 is in communication with a counter configuredto maintain a usage count of the inner core 9222. In certain instances,the control circuit 9260 is configured to store the usage in a memoryunit, for example.

Furthermore, if 9354 the usage count becomes equal to a predeterminedthreshold number, the process 9355 further determines whether the innercore 9222 is disconnected from the disposable outer housing 9224. Thedisconnection indicates a termination of the usage, or completion of theprocedure, that constitutes an end-of-life event based on the usagecount. If 9355 it is so, the disconnection triggers a disabling event9356 of the inner core 9222 to prevent unsafe usage beyond thepredetermined end-of-life usage count. Normal operation 9357, however,is continued until the disconnection is detected.

Various suitable mechanisms can be employed to disable the inner core9222 at an end-of-life event. In at least one example, the controlcircuit 9260 employees a current limiter to ensure that current withinthe inner core is maintained below a predetermined threshold duringnormal operation. To disable the inner core 9222, the control circuit9260 may remove, disable, or disconnect the current limiter, whichcauses excessive current to pass through the circuitry of the inner core9222 thereby disabling the inner core. Disabling the inner core preventsunauthorized use thereof beyond a predetermined lifecycle carefullyselected to ensure the safe operation of the handle assembly in surgery.

FIGS. 22-25 illustrate a safety mechanism for disabling a disposableouter housing 9424 of a handle assembly 9420 to protect against unsafereuse of the disposable outer housing 9424 beyond its designcapabilities. The handle assembly 9420 is similar in many respects toother handle assemblies described elsewhere herein, which are notrepeated herein for brevity. For example, like the disposable outerhousing 9224, the disposable outer housing 9424 is configured toselectively receive and encase inner core 9422 to establish a sterilebarrier around the inner core 9422.

Furthermore, the outer housing 9424 includes two housing portionsmovable relative to one another between a closed, fully coupledconfiguration, and an open, partially detached, or fully detached,configuration to accommodate insertion of the inner core 9422 therein.When joined, the housing portions define a cavity therein in which innercore 9222 may be selectively situated.

The inner core 9422 includes a power source 9426 that can be in the formof one or more batteries. In an assembled configuration, as illustratedin FIG. 22 , connector wires 9427, 9428 electrically connect the innercore 9422 to the disposable outer housing 9424. In various aspects, asillustrated in FIG. 23 , the disposable outer housing 9424 includes oneor more cutting members 9437, 9438 configured to cut, or several, one orboth of the connector wires 9427, 9428 thereby permanently disconnectinga circuit electrically coupling the disposable outer housing 9424 to theinner core 9422, which disables the disposable outer housing 9424, asillustrated in FIG. 24 . In an alternative embodiment, as illustrated inFIG. 25 , connector wires 9447, 9448, which are similar to the connectorwires 9427, 9428, include weekend, or tethering, portions 9457, 9458that are severed when the housing portions of the disposable outerhousing are transitioned to the open configuration.

In certain instances, a connector wire of a disposable outer housing iscoupled to an identifier 9429 of the disposable outer housing. In theexample illustrated in FIG. 24 , the connector wire 9427 is coupled toan RFID chip that is disabled on the connector wire 9427 is cut by thecutting member 9437 during a transition of the disposable outer housing9424 to an open configuration. Disabling the identifier 9429 prevents aninner core from establishing a successful connection with a useddisposable outer housing.

FIGS. 26-27 illustrate additional safety mechanisms for disabling adisposable outer housing 9524 of a handle assembly 9520 to protectagainst unsafe reuse of the disposable outer housing 9524 beyond itsdesign capabilities. The handle assembly 9520 is similar in manyrespects to other handle assemblies described elsewhere herein, whichare not repeated herein for brevity. For example, like the disposableouter housing 9224, the disposable outer housing 9524 is configured toselectively receive and encase inner core 9522 to establish a sterilebarrier 9525 around the inner core 9522.

Furthermore, the outer housing 9524 includes two housing portions 9524a, 9524 b movable relative to one another between a closed, fullycoupled configuration (FIG. 26 ), and an open, partially detached, orfully detached, configuration (FIG. 27 ) to accommodate insertion of theinner core 9522 therein. The handle assembly 9520 further includes anexternal power source 9526 connected via a connector wire 9527 extendingthrough the sterile barrier 9525 to a control circuit 9560. In theillustrated example, the external power source 9526 is releasablymounted onto the disposable outer housing 9524, and the connector wire9527 is severed when the external power source 9526 is released from thedisposable outer housing 9524 after completion of the surgicalprocedure, which disables the disposable outer housing 9524 therebypreventing unsafe reuse thereof. Furthermore, a second wire connector9528, extending between the housing portion 9524 a, 9524 b, can also besevered when the disposable outer handle 9524 is transitioned to theopen configuration to prevent unsafe reuse of the disposable outerhousing 9524.

Further to the above, in various aspects, as illustrated in FIGS. 28-29, one or both of the housing portions 9524 a, 9524 b of a disposableouter housing 9524′ (FIG. 28 ), 9524″ (FIG. 29 ) are equipped with amechanical connector 9531 (FIG. 28 ), 9551 (FIG. 29 ) that maintains thehousing portions 9524 a, 9524 b in a closed configuration, and issevered or broken when the housing portions 9524 a, 9524 b are pulledapart after completion of a surgical procedure to recover the inner core9522, for example.

Referring now to FIGS. 30-34 , a surgical instrument system 9600 issimilar in many respects to the surgical instrument systems 8500, 8800.For example, the surgical instrument system 9600 also includes a handleassembly 9620 that includes an inner core which has a motor assembly formotivating one or more drive members configured to effect a closuremotion, an articulation motion, and/or a firing motion of an endeffector 9640. A shaft assembly 9630 extends between the end effector9640 and the handle assembly 9620 to transmit drive motion from theinner core to the end effector 9640 to deploy staples from a staplecartridge 9641.

The handle assembly 9620 includes a power source 9626 that can be in theform of one or more batteries. A sterilization-detection circuit 9660 iscoupled to the power source 9626 and to a receiver 9663 connected to asensor array 9670 configured to monitor a sterilization status of thehandle assembly 9620. The sensor array 9670 includes a number of sensors9671 disposed onto an outer surface 9623 of the disposable outer housing9624. The sensors 9671 are configured to detect the sterilizationstatuses of various portions, or zones, of the handle assembly 9620,which are then communicated to a microcontroller 9661. Themicrocontroller 9661 causes a user interface 9662 to present thesterilization statuses, as illustrated in FIG. 34 .

In the illustrated example, the user interface 9662 is in the form of anLED display. A representation of the handle assembly 9620 is displayedonto the LED display. Each of the various portions, or zones, of thehandle assembly 9620 is shown in one of two different visual indicatorsrepresenting either an acceptable sterilization status or anunacceptable sterilization status. The microcontroller 9661 assigns oneof the two visual indicators to each of the zones based on at least onereading of at least one of the sensors 9671 in such zone. In theillustrated example, zones 2, 5 are assigned an unacceptablesterilization status, while zones 1, 3, 4, 6 are assigned an acceptablesterilization status.

In certain instances, a handle assembly such as, for example, the handleassembly 9620 is re-usable. Accordingly, the handle assembly 9620 isre-sterilized before each use to maintain a sterile surgical field whileusing the handle assembly 9620 in surgery. In the illustrated example,the handle assembly 9620 is sterilized by exposure to hydrogen peroxide(H₂O₂). In at least one example, a clinician may wipe the handleassembly 9620 with hydrogen peroxide wipes to sterilize the handleassembly 9620. In other examples, other means of sterilizing the handleassembly 9620 via hydrogen peroxide can be employed, as describedelsewhere in the present disclosure in greater detail.

In certain instances, a handle assembly may include a disposable outerhousing and a reusable inner core. In such instances, the sensors 9671can be disposed onto an outer surface of the inner core to evaluatesterilization statuses of various portions, or zones, of the inner corein a similar manner to that described in connection with the handleassembly 9620.

In the event hydrogen peroxide is employed, the sensors 9671 of thesensor array 9670 are hydrogen peroxide sensors configured to detect thepresence of hydrogen peroxide in each of the zones of the handleassembly 9620. Accordingly, the sensor readings of a sensor 9671 canindicate the amount of hydrogen peroxide detected by the sensor 9671 ina portion, or zone, of the handle assembly 9620 where the sensor 9671resides. As illustrated in graph 9672 of FIG. 35 , an acceptablesterilization status corresponds to a reading of the sensor 9671 that isgreater than or equal to a predetermined threshold 9673.

Further to the above, FIG. 36 is a logic flow diagram of a process 9680depicting a control program or a logic configuration for detecting anend of a lifecycle of a re-serializable component of a surgicalinstrument system such, as for example, a handle assembly or an innercore. The process 9680 detects the end of the lifecycle by counting thenumber of times the component has been re-sterilized.

In at least one example, the process 9680 can be implemented by thesterilization-detection circuit 9660. If 9681 the microcontroller 9661detects a sensor reading greater than or equal to the predeterminedthreshold 9673, the microcontroller 9661 increases a count kept by anysuitable counter by one. In the event, the re-sterilization is performedby hydrogen peroxide, the sensor reading increases to reach a peakvalue, then decreases as the hydrogen peroxide begins to evaporate, asillustrated in FIG. 35 . To avoid false counts, the microcontroller 9661is configured to ignore 9683 sensor readings for a predetermined timeperiod.

In certain instances, as illustrated in FIG. 37 , a component of asurgical instrument system such as, for example, a handle assembly 9720includes an outer surface 9723 coated with a coating that changes colorupon exposure to a sterilization solution such as, for example, hydrogenperoxide. The coating provides a visual indicator of areas 9720 a of thehandle assembly 9720 that have been sufficiently exposed to hydrogenperoxide and areas 9720 b that have not been sufficiently exposed tohydrogen peroxide. This gives the clinician a chance to ensureapplication of the sterilization solution to all portions of the handleassembly 9720 with sufficient quantities to yield a properly sterilizedhandle assembly 9720′.

Referring now to FIGS. 38-40 , a re-sterilization system 9800 isdepicted. The re-sterilization system 9800 includes a receiving chamber9801 configured to accommodate a re-usable handle assembly 9820 of asurgical instrument system. In other instance, however, there-sterilization system 9800 can be configured to accommodate othercomponents of a surgical instrument system such as, for example, aninner core a handle assembly.

In the illustrated example, the re-sterilization system 9800 includestwo portions 9800 a, 9800 b movable between an open configuration, FIG.38 , and a closed configuration, FIG. 39 , to accommodate the re-usablehandle assembly 9820. A receiving chamber 9801 is defined between theportions 9800 a, 9800 b of the re-sterilization system 9800.Furthermore, a number of irrigation ports 9806 are defined in theportion 9800 b. Additionally, or alternatively, irrigation ports can bedefined in the portion 9800 a. Furthermore, the re-sterilization system9800 includes a charging port 9804 and corresponding connectors 9805configured to connect the handle assembly 9820 to a charging systemwhile the handle assembly 9820 is in the receiving chamber.

In various aspects, the irrigation ports 9802 are connected to a sourceof sterilization solution that is delivered through the irrigation ports9802 into the receiving chamber 9801. A pump can be utilized to injectthe sterilization solution through the irrigation ports 9802 and toremove it in a re-sterilization cycle. In an alternative embodiment, asillustrated in FIG. 39 , a re-sterilization system 9800′ includes areceiving chamber 9811 that includes an absorbent material or cloth 9812saturated with a sterilization solution. A motor 9814 causes a driver9813 to repeatedly move the cloth 9812 between a starting position andan end position relative to a handle assembly 9820 to re-sterilize thehandle assembly. Alternatively, the motor 9814 may cause the driver 9813to move the handle assembly 9820 between a starting position and an endposition relative to the cloth 9812.

Referring now to FIGS. 15 and 41 , in certain instances, the primaryinterface assembly 9270 includes a wireless electrical interface 9230and a wired electrical interface 9240. As illustrated in FIG. 41 , thewireless electrical interface 9230 and the wired electrical interface9240 are configured to transmit at least one of data and power throughthe sterile barrier 9225. The at least one of power and data can betransmitted between the inner core 9222 and an end effector and/or ashaft assembly of the surgical instrument system 9200. In variousaspects, the first wireless interface portion 9231 and the secondwireless interface portion 9232 are configured to cooperatively form awireless segment of an electrical pathway between the inner core 9222and the end effector and/or between the inner core 9222 and the shaftassembly. Additionally, one or more flex circuits can be configured todefine one or more segment of the electrical pathway.

In the illustrated example, the wireless electrical interface 9230includes a first wireless interface portion 9231 housed by the innercore 9222, and a second wireless interface portion 9232 releasablyattachable to an outer wall 9227 of the disposable outer housing 9224.In other examples, the second wireless interface portion 9232 isintegrated with the outer wall 9227 of the disposable outer housing9224. In the illustrated example, the first wireless interface portion9231 is located within an outer wall 9229 of the inner core 9222. Inother examples, however, the first wireless interface portion 9231 canbe, at least partially, disclosed on an outer surface of the outer wall9229.

Further to the above, second wireless interface portion 9232 ismagnetically couplable to the first wireless interface portion 9231 whenthe inner core 9222 is properly positioned within the disposable outerhousing 9224. In the illustrated example, the second wireless interfaceportion 9232 includes attachment elements 9233′, 9234′ thereforemagnetically couplable to corresponding attachment elements 9233, 9234of the first wireless interface portion 9231. In certain instances, theattachment elements 9233′, 9234′ are magnetic elements, and thecorresponding attachment elements 9233, 9234 are ferrous elements. Inother instances, the attachment elements 9233′, 9234′ are ferrouselements, and the corresponding attachment elements 9233, 9234 aremagnetic elements. In other instances, the attachment elements 9233′,9234′ and the corresponding attachment elements 9233, 9234 are magneticelements.

The attachment elements 9233, 9234, 9233′, 9234′ cooperate to ensure aproper alignment between an inductive element 9235 of the first wirelessinterface portion 9231 and a corresponding inductive element 9235′ ofthe second wireless interface portion 9232, as illustrated in FIG. 41 .In the illustrated example, the inductive elements 9235, 9235′ are inthe form of wound wire coils that are components of inductive circuits9236, 9236′, respectively. The wire coils of the inductive elements9235, 9235′ comprise a copper, or copper alloy, wire; however, the wirecoils may comprise suitable conductive material, such as aluminum, forexample. The wire coils can be wound around a central axis any suitablenumber of times.

When a proper magnetic attachment is established by the elements 9233,9234, 9233′, 9234′, as illustrated in FIG. 41 , the wire coils of theinductive elements 9235, 9235′ are properly aligned about a central axisextending therethrough. The proper alignment of the wire coils of theinductive elements 9235, 9235′ improves the wireless transmission of theat least one of data and power therethrough.

Further to the above, the wired electrical interface 9240 includes afirst wired interface portion 9241 on the first side of the sterilebarrier 9225, and a second wired interface portion 9242 on the secondside of the sterile barrier 9225. In the example illustrated in FIG. 41, the wired electrical interface 9240 further includes connectors 9243,9243′ configured to cooperate with the first wired interface portion9241 and second wired interface portion 9242 to facilitate a wiredtransmission of at least one data and power through the sterile barrier9225 without contaminating the sterile environment protected by thesterile barrier 9225.

In the illustrated example, the wired electrical interface 9240 definestwo wired electrical pathways extending through the sterile barrier9225. In other examples, however, the wired electrical interface 9240may define more or less than two wired electrical pathways.

The connectors 9243, 9243′ include bodies 9244, 9244′ that extendthrough the outer wall 9227 of the disposable outer housing 9224. Theconnectors 9243, 9243′ further include inner contacts 9245, 9245′ thatare inside the disposable outer housing 9224, and outer contacts 9246,9246′ that are outside the disposable outer housing 9224. In theillustrated example, the second wired interface portion 9242 includesflex circuits 9250, 9250′ terminating at connectors 9247, 9247′configured to form a sealed connection with the outer contacts 9246,9246′. In the illustrated example, the connectors 9247, 9247′ compriseinsulative outer housings 9248, 9248′ configured to receive and guidethe outer contacts 9246, 9246′ into an electrical engagement withcorresponding electrical contacts of the flex circuit 9250, 9250′.

In various examples, the bodies 9244, 9244′ are tightly fitted throughthe outer wall 9227 of the disposable outer housing 9224 to prevent, orat least resist, fluid contamination. In addition, the insulative outerhousings 9248, 9248′ comprise flush ends that rest against an outersurface of the outer wall 9227 to prevent, or at least resist, fluidcontact with the outer contacts 9246, 9246′ in operation.

Furthermore, the inner contacts 9245, 9245′ of the connectors 9243,9243′ are configured to engage leaf spring contacts 9249, 9249′ when theinner core 9222 is properly assembled with the disposable outer housing9224. In the illustrated example, the outer walls 9227, 9229 compriseportions that are flush with one another to facilitate the wirelessconnection between the first wireless interface portion 9231 and thesecond wireless interface portion 9232. In addition, the outer walls9227, 9229 also comprise portions that are spaced apart to facilitatethe wired connection between the inner contacts 9245, 9245′ and the leafspring contacts 9249, 9249′. In the illustrated example, a portion ofthe outer wall 9227 is slightly raised, which forms an isolated chamber9255 between the outer walls 9227, 9229. The isolated chamber 9255 has apredetermined depth that ensures a good electrical contact between theinner contacts 9245, 9245′ and the leaf spring contacts 9249, 9249′ inthe assembled configuration, as illustrated in FIG. 41 .

In various aspects, one or more of the surgical instrument systems ofthe present disclosure include a display for providing feedback to auser, which may include information about one or more characteristics ofthe tissue being treated and/or one or more parameters of the surgicalinstrument system. For example, the display may provide the user withinformation regarding the size of a staple cartridge assembled was thesurgical instrument system and/or a measured thickness of the tissuebeing treated. In various aspects, the display can be a flexibledisplay, for example.

In the example illustrated in FIG. 41 , a flexible display 9201 isincorporated into the disposable outer housing 9224. A microcontroller9202 resides beneath the flexible display 9201. The flexible display9201 is configured to face the outside of the disposable outer housing9224, while the microcontroller 9202 is configured to face the inside ofthe disposable outer housing 9224. The flexible display 9201 canconnected through a wireless or a wired electrical interface to asuitable power source. In at least one example, the flexible display9201 is powered by the power source 9226 of the inner core 9222. In atleast one example, the flexible display 9201 is powered by an externalpower source attachable to the disposable outer housing 9224.

In other examples, the flexible display 9201 can be incorporated into ashaft of a surgical instrument system. In such examples, the flexibledisplay 9201 is bent to conform to, or at least substantially conformto, the cylindrical shape of the shaft. In certain instances, theflexible display 9201 is incorporated into an outer wall of the shaft.In other instances, however, the flexible display 9201 is positionedunderneath, or inside, the shaft, and is visible through a clear outerwall of the shaft. Positioning the flexible display 9201 on thedisposable outer housing 9224, or within the shaft, helps against fogaccumulation on the display which may occur if a display is located withthe inner core 9222 inside the disposable outer housing 9224 due to theheat generated by the motor assembly of the inner core 9222.

Referring now to FIGS. 42-44 , an actuator 10000 can be incorporatedinto a handle assembly of a surgical instrument system such as, forexample, the handle assembly 8520 of the surgical instrument system8500, the handle assembly 9220 of the surgical instrument system 9200,and/or the handle assembly 9120 of the surgical instrument system 9100.The actuator 10000 can be configured to cause an inner core 8522, forexample, to produce drive motions to close, fire, and/or articulate theend effector 8540 that are proportional a mechanical pressure applied bya user, as detected by the actuator 10000. In various aspects, theactuator 10000 comprises a magnetostrictive transducer configured tochange a magnetic field in response to the amount of force appliedthereto. FIG. 43 illustrates different actuation configurations of theactuator 10000, and the amount of strain produced from nullmagnetization (configuration 1) to full magnetization (configurations 1,5). The actuator 10000 is divided into discrete mechanical and magneticattributes that are coupled in their effect on the magnetostrictive corestrain and magnetic induction.

Referring still to FIG. 43 , where no magnetic field is applied, achange in length will also be null along with the magnetic inductionproduced. Further, the amount of the magnetic field (H) is increased toits saturation limits (±Hsat) at configurations 1, 5. This causes anincrease in the axial strain to a maximum value. Configurations 2, 4represent an intermediate increase in the value of the magnetization butto a lesser extent (±H₁) than the configurations 1, 5. The maximumstrain saturation and magnetic induction is obtained at the saturationlimits (±Hsat). Flux lines associated with configurations 1, 2 are inthe opposite direction to flux lines of configurations 4, 5. These fluxfields produced are measured using the principle of Hall Effect or bycalculating the voltage produced in a conductor kept in right angle tothe flux produced, for example. This value will be proportional to theinput strain or force.

Accordingly, a control circuit 8560, for example, may adjust the drivemotions produced by the inner core 8522, for example, based on readingsof a magnetic sensor configured to measure the flux fields generated bythe actuator 10000 in response to an actuation force applied by a userto the actuator 10000. FIG. 44 is a graph 10001 that illustrates changesin closure position (Y-axis) of the jaws of the end effector 8540, forexample, in response to actuation force (X-axis) applied by a user, asdetected by the actuator 10000. In the illustrated example, a fullyclosed configuration of the end effector 8540 corresponds to apredetermined actuation force threshold 10002, which corresponds toconfiguration 5 of the actuator 10000, as illustrated in FIG. 43 . Ifthe predetermined actuation force threshold 10002 is detected by thecontrol circuit 8560, based on readings of the magnetic sensor, thecontrol circuit 8560 causes the drive motions to stop by deactivatingone or more motors of the inner core 8522, for example. Furthermore, thecontrol circuit 8560 may further reverse the direction of rotation ofthe motor to transition the end effector 8540 back to the openconfiguration.

The example illustrated in FIGS. 42-44 illustrate the utilization of theactuator 10000 as an end effector closure actuator. In other examples,the actuator 10000 can be similarly utilized to effect and control afiring motion and/or an articulation motion of the end effector 8540,for example.

Referring now to FIGS. 45 and 46 , a handle assembly 9920 is similar inmany respects to other handle assemblies described elsewhere herein suchas, for example, the handle assemblies 8520, 9120, 9220, which are notrepeated herein for brevity. For example, the handle assembly 9920 alsoincludes an inner core 9922 which has a motor assembly for motivatingone or more drive members configured to effect a closure motion, anarticulation motion, and/or a firing motion in an end effector (e.g. endeffector 8540). The handle assembly 9920 further includes a disposableouter housing 9924 that includes two housing portions 9924 a, 9924 breleasably attached to one another to permit assembly with the innercore 9922. When joined, the housing portions 9924 a, 9924 b define acavity therein in which inner core 9922 may be selectively situatedwithin a sterile barrier 9925 defined by an outer wall 9927 of thedisposable outer housing 9924.

Further to the above, the handle assembly 9920 includes an actuator 9901configured to transform changes in an external actuation force (F)applied by a user to the actuator 9901 into changes in an internalmagnetic field detectable by one or more magnetic field sensors 9902within the handle assembly 9920. The actuator 9901 permits an accuratedetection by the inner core 9922 of the changes in the externalactuation force (F) without compromising the sterile barrier 9925.

In the illustrated example, the housing portion 9924 b includes apressure-sensitive actuation member 9923 configured to detect thechanges in the external actuation force (F). A stem 9905 extends fromthe pressure-sensitive actuation member 9923 inside the disposable outerhousing 9924, and is configured to abut against a rigid surface 9906 ofthe inner core 9922 when the inner core 9922 is properly assembled withthe disposable outer housing 9924, as illustrated in FIG. 46 . A wirecoil 9903 is wound around the stem 9905, and is configured to form amagnetic field when a current is passed therethrough. In at least oneexample, the wire coil 9903 is a part of a circuit powered by a powersource 9926 of the inner core 9922, for example. In a similar manner tothat described in connection with the actuator 10000, changes in theexternal actuation forces (F) applied to the pressure-sensitiveactuation member 9923 cause changes in a magnetic field generated by thewire coil 9903, which correspond to the changes in the externalactuation forces (F).

In the illustrated example, the inner core 9922 includes a controlcircuit 9960 connected to the magnetic field sensor 9902. The controlcircuit 9960 is also connected to a motor assembly 9962 of the innercore 9922, and is configured to cause the motor assembly 9962 to adjustdrive motions generated by the motor assembly 9962 in accordance withchanges in the external actuation forces (F) as detected by the controlcircuit 9960 based on readings of the magnetic field sensor 9902. Invarious aspects, the drive motions are configured to close, fire, and/orarticulate an end effector operably coupled to the hand assembly 9920.In certain aspects, the control circuit 9960 includes a storage mediumsuch as, for example, a memory unit that stores one or more databases,formulas, and/or tables that can be utilized to select one or moreparameters of the drive motions based on the readings of the magneticfield sensor 9902.

In various aspects, the wire coil 9903 comprise a copper, or copperalloy, wire; however, the wire coil 9903 may comprise suitableconductive material, such as aluminum, for example. The wire coil 9903can be wound around the stem 9905 any suitable number of times.

Referring now to FIGS. 47 and 48 , a handle assembly 11020 is similar inmany respects to other handle assemblies described elsewhere herein suchas, for example, the handle assemblies 9920, 8520, 9120, 9220, which arenot repeated herein for brevity. For example, the handle assembly 11020also includes an inner core 11022 which has a motor assembly formotivating one or more drive members configured to effect a closuremotion, an articulation motion, and/or a firing motion in an endeffector (e.g. end effector 8540). The handle assembly 11020 furtherincludes a disposable outer housing 11024 that includes two housingportions 11024 a, 11024 b releasably attached to one another to permitassembly with the inner core 11022. When joined, the housing portions11024 a, 11024 b define a cavity therein in which inner core 11022 maybe selectively situated within a sterile barrier 11025 defined by anouter wall 11027 of the disposable outer housing 11024.

Further to the above, the handle assembly 11020 includes an actuator11001 configured to detect an external compression force (F) applied bya user to the actuator 9901 and, in response, cause an electromechanicalmember 11023 to produce vibrations when the external actuation force (F)is greater than or equal to a predetermined threshold 11002, asillustrated in graph 11004 of FIG. 49 . In at least one example, theelectromechanical member 11023 is in the form of a piezoelectric filmor, alternatively, a ceramic member. The electromechanical member 11023is coupled to a power source 11026 of the inner core 11022 whichsupplies power to the electromechanical member 11023 when a conductivemember 11003 closes a circuit connecting the electromechanical member11023 to the power source 11026.

Referring now to FIGS. 50 and 51 , a handle assembly 12020 is similar inmany respects to other handle assemblies described elsewhere herein suchas, for example, the handle assemblies 9920, 8520, 9120, 9220, 11020,which are not repeated herein for brevity. For example, the handleassembly 12020 also includes an inner core 12022 which has a motorassembly for motivating one or more drive members configured to effect aclosure motion, an articulation motion, and/or a firing motion in an endeffector (e.g. end effector 8540). The handle assembly 12020 furtherincludes a disposable outer housing 12024 that includes two housingportions releasably attached to one another to permit assembly with theinner core 12022. When joined, the housing portions define a cavitytherein in which inner core 12022 may be selectively situated within asterile barrier 12025 defined by an outer wall 12027 of the disposableouter housing 12024.

Further to the above, the handle assembly 12020 includes an actuator12001 configured to detect an external compression force (F) applied bya user to the actuator 12001. The detection occurs across the sterilebarrier 12025. Said another way, the external compression force (F) isapplied on a first side of sterile barrier 12025, and is detected on asecond side, opposite the first side, of the sterile barrier 12025,without compromising the sterile barrier 12025. In the illustratedexample, the actuator 12001 includes components on both sides of thesterile barrier 12025 that are capable of a magnetic interaction acrossthe sterile barrier 12025. A ferromagnetic plate, or film, 12002 ispositioned outside the disposable outer housing 12024, and acorresponding magnetic sensor 12003 is positioned inside the disposableouter housing 12024. A movement of the ferromagnetic plate 12002, inresponse to the external compression force (F), causes a change in thereadings of the magnetic sensor 12003 commensurate with the change inposition of the ferromagnetic plate 12002 caused by the externalcompression force (F).

Furthermore, a control circuit 120060 of the handle assembly 12020 mayinclude a microcontroller 120061 configured to adjust drive motions of amotor assembly 120062 in accordance with the readings of the magneticsensor 12003. The drive motions may effect one or more of a closuremotion, a firing motions, and an articulation motion of an end effector,for example.

In the illustrated example, the ferromagnetic plate 12002 extends acrossa cavity 12031 defined in the outer wall 12027 of the disposable outerhousing 12024. Edges of the ferromagnetic plate 12002 or attached tosidewalls of the cavity 12031. In the illustrated example, form-in-placeseals 12029, 12030 are configured to attach the edges of theferromagnetic plate 12002 to the sidewalls of the cavity 12031. However,in other examples, it is envisioned that other attachment mechanisms canbe employed. In at least one example, an adhesive can be utilized toattach the edges of the ferromagnetic plate 12002 to the sidewalls ofthe cavity 12031.

Further to the above, the magnetic sensor 12003 protrudes through anouter wall 12028 of the inner core 12022, and is compressed by a spring12004 against the outer wall 12027. The spring 12004 ensures that themagnetic sensor 12003 remains in sufficient proximity to theferromagnetic plate 12002 to detect changes in the position of theferromagnetic plate 12002 caused by the external compression force (F).

When the inner core 12022 is properly assembled with the disposableouter housing 12024, the magnetic sensor 12003 and the ferromagneticplate 12002 are aligned with each other on opposite sides of a wallportion of the outer wall 12027 that forms the cavity 12031. Theferromagnetic plate 12002 is configured to move, or bend, toward themagnetic sensor 12003 in response to the external compression force (F).The movement of the ferromagnetic plate 12002 changes the readings ofthe magnetic sensor 12003 in accordance with the magnitude of theexternal compression force (F). When the user releases the ferromagneticplate 12002, or reduces the external compression force (F), theferromagnetic plate 12002 returns to its natural state, moving away fromthe magnetic sensor 12003, which changes the readings of the magneticsensor 12003 in accordance with the reduction in the externalcompression force (F). As described above, the microcontroller 120061 isin communication with the magnetic sensor 12003. Accordingly, thechanges in the readings of the magnetic sensor 12003 are translated intochanges and drive motions of the motor assembly 120062.

Referring now to FIGS. 52-54 , alternative actuator embodiments aredepicted. FIG. 52 illustrates a handle assembly 13020 similar in manyrespects to handle assemblies described elsewhere herein such as, forexample, the handle assemblies 9920, 8520, 9120, 9220, 11020, 12020,which are not repeated for brevity. For example, the handle assembly13020 also includes an inner core 13022 which has a motor assembly formotivating one or more drive members configured to effect a closuremotion, an articulation motion, and/or a firing motion in an endeffector (e.g. end effector 8540). The handle assembly 13020 furtherincludes a disposable outer housing 13024 that includes two housingportions releasably attached to one another to permit assembly with theinner core 13022. When joined, the housing portions define a cavitytherein in which inner core 13022 may be selectively situated within asterile barrier 13025 defined by an outer wall 13027 of the disposableouter housing 13024.

Further to the above, the handle assembly 13020 includes an actuator13001 similar in many respects to the actuator 12001, which are notrepeated for brevity. The actuator 13001 includes a ferromagnetic plate13002 similar in many respects to the ferromagnetic plate 12002. Inaddition, the ferromagnetic plate 13002 is connected to the inner core13022 via wire connectors 13023 that extend through an outer wall of theinner core 13022. Furthermore, an adhesive 13029 is configured toseemingly secure the ferromagnetic plate 13002 to an opening 13031 ofthe disposable outer housing 13024. In the illustrated example, theferromagnetic plate 13002 defines a portion of the outer wall 13027.

In the examples illustrated in FIGS. 53 and 54 , a flexible rubberizedouter cover 13033 is disposed over the ferromagnetic plate 13002 forminga portion of the outer wall 13027. The flexible rubberized outer cover13033 can be attached to the outer wall 13027 via a form-in-place sealand/or an adhesive 13034. The ferromagnetic plate 13002 and the flexiblerubberized outer cover 13033 provide a double seal that ensures theintegrity of the sterile barrier 13025.

The surgical instrument systems described herein are motivated by anelectric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In certain instances,the motors disclosed herein may comprise a portion or portions of arobotically controlled system. U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example,discloses several examples of a robotic surgical instrument system ingreater detail, the entire disclosure of which is incorporated byreference herein. The disclosures of International Patent PublicationNo. WO 2017/083125, entitled STAPLER WITH COMPOSITE CARDAN AND SCREWDRIVE, published May 18, 2017, International Patent Publication No. WO2017/083126, entitled STAPLE PUSHER WITH LOST MOTION BETWEEN RAMPS,published May 18, 2017, International Patent Publication No. WO2015/153642, entitled SURGICAL INSTRUMENT WITH SHIFTABLE TRANSMISSION,published Oct. 8, 2015, U.S. Patent Application Publication No.2017/0265954, filed Mar. 17, 2017, entitled STAPLER WITH CABLE-DRIVENADVANCEABLE CLAMPING ELEMENT AND DUAL DISTAL PULLEYS, U.S. PatentApplication Publication No. 2017/0265865, filed Feb. 15, 2017, entitledSTAPLER WITH CABLE-DRIVEN ADVANCEABLE CLAMPING ELEMENT AND DISTALPULLEY, and U.S. Patent Application Publication No. 2017/0290586,entitled STAPLING CARTRIDGE, filed on Mar. 29, 2017, are incorporatedherein by reference in their entireties.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

EXAMPLES

Various aspects of the subject matter described herein are set out inthe following numbered examples.

Example 1—A modular surgical instrument system that comprises modularcomponents, comprising a shaft and a handle assembly releasablycouplable to the shaft. The handle assembly comprises a disposable outerhousing configured to define a sterile barrier. The disposable outerhousing comprises a first housing-portion and a second housing-portionmovable relative to the first housing-portion between an openconfiguration and a closed configuration. The handle assembly furthercomprises a control inner core receivable inside the disposable outerhousing in the open configuration. The disposable outer housing isconfigured to isolate the control inner core in the closedconfiguration. The modular components further comprise a loading unitreleasably couplable to the shaft, wherein the loading unit comprises anend effector. The modular components further comprise a staple cartridgereleasably couplable to the end effector. The modular surgicalinstrument system further comprises a control circuit electricallycouplable to the modular components. The control circuit configured togenerate an interrogation signal, detect a response signal to theinterrogation signal, determine a modular configuration of the modularsurgical instrument system based on the response signal, and assessauthenticity of the modular configuration based on the response signal.

Example 2—The modular surgical instrument system of Example 1, whereinthe control circuit is configured to determine the modular configurationby determining a total sensed resistance based on the response signal,and wherein the total sensed resistance is indicative of the modularconfiguration.

Example 3—The modular surgical instrument system of Example 2, whereinthe control circuit is configured to assess the authenticity of themodular configuration based on a comparison between an expected valueand a determined value of the total sensed resistance.

Example 4—The modular surgical instrument system of Examples 2 or 3,wherein the control circuit is configured to compare a magnitude of adeviation between an expected value and a determined value of the totalsensed resistance to a predetermined threshold.

Example 5—The modular surgical instrument system of Examples 2, 3, or 4,wherein the control circuit is configured to select a security responsebased on a magnitude of a deviation between an expected value and adetermined value of the total sensed resistance.

Example 6—The modular surgical instrument system of Example 5, whereinthe security response comprises at least temporarily deactivating atleast one of power and communications within the modular configuration.

Example 7—The modular surgical instrument system of Examples 2, 3, 4, 5,or 6, wherein the control circuit is configured to determine at leastone of a connection status and an authentication status of at least oneof the modular components of the modular configuration based on amagnitude of a deviation between an expected value and a determinedvalue of the total sensed resistance.

Example 8—A modular surgical instrument system that comprises modularcomponents characterized by unique identifier resistances. The modularcomponents comprise a shaft and a handle assembly releasably couplableto the shaft. The handle assembly comprises a disposable outer housingconfigured to define a sterile barrier. The disposable outer housingcomprises a first housing-portion and a second housing-portion movablerelative to the first housing-portion between an open configuration anda closed configuration. The handle assembly further comprises a controlinner core receivable inside the disposable outer housing in the openconfiguration. The disposable outer housing is configured to isolate thecontrol inner core in the closed configuration. The modular componentsfurther comprise a loading unit releasably couplable to the shaft,wherein the loading unit comprises an end effector. The modularcomponents further comprise a staple cartridge releasably couplable tothe end effector. The modular surgical instrument system furthercomprises a control circuit electrically couplable to the modularcomponents. The authentication circuit is configured to detect a modularconfiguration of the modular surgical instrument system based on theunique identifier resistances and assess authenticity of the modularconfiguration.

Example 9—The modular surgical instrument system of Example 8, whereinthe control circuit is configured to assess the authenticity of themodular configuration based on a comparison between expected anddetermined values of the unique identifier resistances.

Example 10—The modular surgical instrument system of Examples 8 and 9,wherein the control circuit is configured to compare a magnitude of adeviation between expected and determined values of the uniqueidentifier resistances.

Example 11—The modular surgical instrument system of Examples 8, 9, or10, wherein the control circuit is configured to determine at least oneof a connection status and an authentication status of at least one ofthe modular components of the modular configuration based on a magnitudeof a deviation between expected and determined values of the uniqueidentifier resistances.

Example 12—The modular surgical instrument system of Examples 8, 9, 10,or 11, wherein the control circuit is configured to select a securityresponse based on a magnitude of a deviation between expected anddetermined values of the unique identifier resistances.

Example 13—The modular surgical instrument system of Example 12, whereinthe security response comprises a temporary deactivation of one or moreaspects of the modular surgical instrument system.

Example 14—A modular surgical instrument system that comprises modularcomponents characterized by unique identifier resistances. The modularcomponents comprise a shaft and a handle assembly releasably couplableto the shaft. The handle assembly comprises a disposable outer housingconfigured to define a sterile barrier. The disposable outer housingcomprises a first housing-portion and a second housing-portion movablerelative to the first housing-portion between an open configuration anda closed configuration. The handle assembly further comprises a controlinner core receivable inside the disposable outer housing in the openconfiguration. The disposable outer housing is configured to isolate thecontrol inner core in the closed configuration. The modular componentsfurther comprise a loading unit releasably couplable to the shaft,wherein the loading unit comprises an end effector. The modularcomponents further comprise a staple cartridge releasably couplable tothe end effector. The modular surgical instrument system furthercomprises a control circuit electrically couplable to the modularcomponents. The authentication circuit is configured to detect anidentification signal of a modular configuration of the modular surgicalinstrument system, measure a characteristic of the modularconfiguration, determine an authentication key based on at least onemeasurement of the characteristic of the modular configuration, andauthenticate the identification signal based on the authentication key.

Example 15—The modular surgical instrument system of Example 14, whereinthe control circuit is configured to determine the authentication keyindependently of the identification signal.

Example 16—The modular surgical instrument system of Examples 14 or 15,wherein the authentication key is based on a characteristic common amongindividual modular components of the modular configuration.

Example 17—The modular surgical instrument system of Example 16, whereinthe characteristic is an environmental characteristic.

Example 18—The modular surgical instrument system of Example 16, whereinthe characteristic is selected from the group consisting of a location,a radio-frequency (RF) intensity, a sound level, a light level, amagnetic field strength, and combinations thereof.

Example 19—The modular surgical instrument system of Examples 14, 15,16, 17, or 18, wherein control circuit is configured to utilize theauthentication key to decode the identification signal.

Example 20—The modular surgical instrument system of Examples 14 or 15,wherein the authentication key is based on a magnetic field strengthmeasured by the modular configuration.

While several forms have been illustrated and described, it is not theintention of Applicant to restrict or limit the scope of the appendedclaims to such detail. Numerous modifications, variations, changes,substitutions, combinations, and equivalents to those forms may beimplemented and will occur to those skilled in the art without departingfrom the scope of the present disclosure. Moreover, the structure ofeach element associated with the described forms can be alternativelydescribed as a means for providing the function performed by theelement. Also, where materials are disclosed for certain components,other materials may be used. It is therefore to be understood that theforegoing description and the appended claims are intended to cover allsuch modifications, combinations, and variations as falling within thescope of the disclosed forms. The appended claims are intended to coverall such modifications, variations, changes, substitutions,modifications, and equivalents.

The foregoing detailed description has set forth various forms of thedevices and/or processes via the use of block diagrams, flowcharts,and/or examples. Insofar as such block diagrams, flowcharts, and/orexamples contain one or more functions and/or operations, it will beunderstood by those within the art that each function and/or operationwithin such block diagrams, flowcharts, and/or examples can beimplemented, individually and/or collectively, by a wide range ofhardware, software, firmware, or virtually any combination thereof.Those skilled in the art will recognize that some aspects of the formsdisclosed herein, in whole or in part, can be equivalently implementedin integrated circuits, as one or more computer programs running on oneor more computers (e.g., as one or more programs running on one or morecomputer systems), as one or more programs running on one or moreprocessors (e.g., as one or more programs running on one or moremicroprocessors), as firmware, or as virtually any combination thereof,and that designing the circuitry and/or writing the code for thesoftware and or firmware would be well within the skill of one of skillin the art in light of this disclosure. In addition, those skilled inthe art will appreciate that the mechanisms of the subject matterdescribed herein are capable of being distributed as one or more programproducts in a variety of forms, and that an illustrative form of thesubject matter described herein applies regardless of the particulartype of signal bearing medium used to actually carry out thedistribution.

Instructions used to program logic to perform various disclosed aspectscan be stored within a memory in the system, such as dynamic randomaccess memory (DRAM), cache, flash memory, or other storage.Furthermore, the instructions can be distributed via a network or by wayof other computer readable media. Thus a machine-readable medium mayinclude any mechanism for storing or transmitting information in a formreadable by a machine (e.g., a computer), but is not limited to, floppydiskettes, optical disks, compact disc, read-only memory (CD-ROMs), andmagneto-optical disks, read-only memory (ROMs), random access memory(RAM), erasable programmable read-only memory (EPROM), electricallyerasable programmable read-only memory (EEPROM), magnetic or opticalcards, flash memory, or a tangible, machine-readable storage used in thetransmission of information over the Internet via electrical, optical,acoustical or other forms of propagated signals (e.g., carrier waves,infrared signals, digital signals, etc.). Accordingly, thenon-transitory computer-readable medium includes any type of tangiblemachine-readable medium suitable for storing or transmitting electronicinstructions or information in a form readable by a machine (e.g., acomputer).

As used in any aspect herein, the term “control circuit” may refer to,for example, hardwired circuitry, programmable circuitry (e.g., acomputer processor including one or more individual instructionprocessing cores, processing unit, processor, microcontroller,microcontroller unit, controller, digital signal processor (DSP),programmable logic device (PLD), programmable logic array (PLA), orfield programmable gate array (FPGA)), state machine circuitry, firmwarethat stores instructions executed by programmable circuitry, and anycombination thereof. The control circuit may, collectively orindividually, be embodied as circuitry that forms part of a largersystem, for example, an integrated circuit (IC), an application-specificintegrated circuit (ASIC), a system on-chip (SoC), desktop computers,laptop computers, tablet computers, servers, smart phones, etc.Accordingly, as used herein “control circuit” includes, but is notlimited to, electrical circuitry having at least one discrete electricalcircuit, electrical circuitry having at least one integrated circuit,electrical circuitry having at least one application specific integratedcircuit, electrical circuitry forming a general purpose computing deviceconfigured by a computer program (e.g., a general purpose computerconfigured by a computer program which at least partially carries outprocesses and/or devices described herein, or a microprocessorconfigured by a computer program which at least partially carries outprocesses and/or devices described herein), electrical circuitry forminga memory device (e.g., forms of random access memory), and/or electricalcircuitry forming a communications device (e.g., a modem, communicationsswitch, or optical-electrical equipment). Those having skill in the artwill recognize that the subject matter described herein may beimplemented in an analog or digital fashion or some combination thereof.

As used in any aspect herein, the term “logic” may refer to an app,software, firmware and/or circuitry configured to perform any of theaforementioned operations. Software may be embodied as a softwarepackage, code, instructions, instruction sets and/or data recorded onnon-transitory computer readable storage medium. Firmware may beembodied as code, instructions or instruction sets and/or data that arehard-coded (e.g., nonvolatile) in memory devices.

As used in any aspect herein, the terms “component,” “system,” “module”and the like can refer to a computer-related entity, either hardware, acombination of hardware and software, software, or software inexecution.

As used in any aspect herein, an “algorithm” refers to a self-consistentsequence of steps leading to a desired result, where a “step” refers toa manipulation of physical quantities and/or logic states which may,though need not necessarily, take the form of electrical or magneticsignals capable of being stored, transferred, combined, compared, andotherwise manipulated. It is common usage to refer to these signals asbits, values, elements, symbols, characters, terms, numbers, or thelike. These and similar terms may be associated with the appropriatephysical quantities and are merely convenient labels applied to thesequantities and/or states.

A network may include a packet switched network. The communicationdevices may be capable of communicating with each other using a selectedpacket switched network communications protocol. One examplecommunications protocol may include an Ethernet communications protocolwhich may be capable permitting communication using a TransmissionControl Protocol/Internet Protocol (TCP/IP). The Ethernet protocol maycomply or be compatible with the Ethernet standard published by theInstitute of Electrical and Electronics Engineers (IEEE) titled “IEEE802.3 Standard”, published in December, 2008 and/or later versions ofthis standard. Alternatively or additionally, the communication devicesmay be capable of communicating with each other using an X.25communications protocol. The X.25 communications protocol may comply orbe compatible with a standard promulgated by the InternationalTelecommunication Union-Telecommunication Standardization Sector(ITU-T). Alternatively or additionally, the communication devices may becapable of communicating with each other using a frame relaycommunications protocol. The frame relay communications protocol maycomply or be compatible with a standard promulgated by ConsultativeCommittee for International Telegraph and Telephone (CCITT) and/or theAmerican National Standards Institute (ANSI). Alternatively oradditionally, the transceivers may be capable of communicating with eachother using an Asynchronous Transfer Mode (ATM) communications protocol.The ATM communications protocol may comply or be compatible with an ATMstandard published by the ATM Forum titled “ATM-MPLS NetworkInterworking 2.0” published August 2001, and/or later versions of thisstandard. Of course, different and/or after-developedconnection-oriented network communication protocols are equallycontemplated herein.

Unless specifically stated otherwise as apparent from the foregoingdisclosure, it is appreciated that, throughout the foregoing disclosure,discussions using terms such as “processing,” “computing,”“calculating,” “determining,” “displaying,” or the like, refer to theaction and processes of a computer system, or similar electroniccomputing device, that manipulates and transforms data represented asphysical (electronic) quantities within the computer system's registersand memories into other data similarly represented as physicalquantities within the computer system memories or registers or othersuch information storage, transmission or display devices.

One or more components may be referred to herein as “configured to,”“configurable to,” “operable/operative to,” “adapted/adaptable,” “ableto,” “conformable/conformed to,” etc. Those skilled in the art willrecognize that “configured to” can generally encompass active-statecomponents and/or inactive-state components and/or standby-statecomponents, unless context requires otherwise.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Those skilled in the art will recognize that, in general, terms usedherein, and especially in the appended claims (e.g., bodies of theappended claims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that if aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even if a specific number of an introduced claim recitationis explicitly recited, those skilled in the art will recognize that suchrecitation should typically be interpreted to mean at least the recitednumber (e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations). Furthermore, in those instances where a conventionanalogous to “at least one of A, B, and C, etc.” is used, in generalsuch a construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, and C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). In those instances where aconvention analogous to “at least one of A, B, or C, etc.” is used, ingeneral such a construction is intended in the sense one having skill inthe art would understand the convention (e.g., “a system having at leastone of A, B, or C” would include but not be limited to systems that haveA alone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that typically a disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms unless context dictates otherwise. For example, the phrase “Aor B” will be typically understood to include the possibilities of “A”or “B” or “A and B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flow diagrams arepresented in a sequence(s), it should be understood that the variousoperations may be performed in other orders than those which areillustrated, or may be performed concurrently. Examples of suchalternate orderings may include overlapping, interleaved, interrupted,reordered, incremental, preparatory, supplemental, simultaneous,reverse, or other variant orderings, unless context dictates otherwise.Furthermore, terms like “responsive to,” “related to,” or otherpast-tense adjectives are generally not intended to exclude suchvariants, unless context dictates otherwise.

It is worthy to note that any reference to “one aspect,” “an aspect,”“an exemplification,” “one exemplification,” and the like means that aparticular feature, structure, or characteristic described in connectionwith the aspect is included in at least one aspect. Thus, appearances ofthe phrases “in one aspect,” “in an aspect,” “in an exemplification,”and “in one exemplification” in various places throughout thespecification are not necessarily all referring to the same aspect.Furthermore, the particular features, structures or characteristics maybe combined in any suitable manner in one or more aspects.

In this specification, unless otherwise indicated, terms “about” or“approximately” as used in the present disclosure, unless otherwisespecified, means an acceptable error for a particular value asdetermined by one of ordinary skill in the art, which depends in part onhow the value is measured or determined. In certain embodiments, theterm “about” or “approximately” means within 1, 2, 3, or 4 standarddeviations. In certain embodiments, the term “about” or “approximately”means within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%,0.5%, or 0.05% of a given value or range.

In this specification, unless otherwise indicated, all numericalparameters are to be understood as being prefaced and modified in allinstances by the term “about,” in which the numerical parameters possessthe inherent variability characteristic of the underlying measurementtechniques used to determine the numerical value of the parameter. Atthe very least, and not as an attempt to limit the application of thedoctrine of equivalents to the scope of the claims, each numericalparameter described herein should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques.

Any numerical range recited herein includes all sub-ranges subsumedwithin the recited range. For example, a range of “1 to 10” includes allsub-ranges between (and including) the recited minimum value of 1 andthe recited maximum value of 10, that is, having a minimum value equalto or greater than 1 and a maximum value equal to or less than 10. Also,all ranges recited herein are inclusive of the end points of the recitedranges. For example, a range of “1 to 10” includes the end points 1 and10. Any maximum numerical limitation recited in this specification isintended to include all lower numerical limitations subsumed therein,and any minimum numerical limitation recited in this specification isintended to include all higher numerical limitations subsumed therein.Accordingly, Applicant reserves the right to amend this specification,including the claims, to expressly recite any sub-range subsumed withinthe ranges expressly recited. All such ranges are inherently describedin this specification.

Any patent application, patent, non-patent publication, or otherdisclosure material referred to in this specification and/or listed inany Application Data Sheet is incorporated by reference herein, to theextent that the incorporated materials is not inconsistent herewith. Assuch, and to the extent necessary, the disclosure as explicitly setforth herein supersedes any conflicting material incorporated herein byreference. Any material, or portion thereof, that is said to beincorporated by reference herein, but which conflicts with existingdefinitions, statements, or other disclosure material set forth hereinwill only be incorporated to the extent that no conflict arises betweenthat incorporated material and the existing disclosure material.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing description ofthe one or more forms has been presented for purposes of illustrationand description. It is not intended to be exhaustive or limiting to theprecise form disclosed. Modifications or variations are possible inlight of the above teachings. The one or more forms were chosen anddescribed in order to illustrate principles and practical application tothereby enable one of ordinary skill in the art to utilize the variousforms and with various modifications as are suited to the particular usecontemplated. It is intended that the claims submitted herewith definethe overall scope.

What is claimed is:
 1. A modular surgical instrument system, comprising:modular components, comprising: a shaft; a handle assembly releasablycouplable to the shaft, wherein the handle assembly comprises: adisposable outer housing configured to define a sterile barrier, thedisposable outer housing comprising: a first housing-portion; and asecond housing-portion movable relative to the first housing-portionbetween an open configuration and a closed configuration; and a controlinner core receivable inside the disposable outer housing in the openconfiguration, wherein the disposable outer housing is configured toisolate the control inner core in the closed configuration; a loadingunit releasably couplable to the shaft, wherein the loading unitcomprises an end effector; and a staple cartridge releasably couplableto the end effector; and a control circuit electrically couplable to themodular components, the control circuit configured to: generate aninterrogation signal; detect a response signal to the interrogationsignal; determine a modular configuration of the modular surgicalinstrument system based on the response signal; and assess authenticityof the modular configuration based on the response signal.
 2. Themodular surgical instrument system of claim 1, wherein the controlcircuit is configured to determine the modular configuration bydetermining a total sensed resistance based on the response signal, andwherein the total sensed resistance is indicative of the modularconfiguration.
 3. The modular surgical instrument system of claim 2,wherein the control circuit is configured to assess the authenticity ofthe modular configuration based on a comparison between an expectedvalue and a determined value of the total sensed resistance.
 4. Themodular surgical instrument system of claim 2, wherein the controlcircuit is configured to compare a magnitude of a deviation between anexpected value and a determined value of the total sensed resistance toa predetermined threshold.
 5. The modular surgical instrument system ofclaim 2, wherein the control circuit is configured to select a securityresponse based on a magnitude of a deviation between an expected valueand a determined value of the total sensed resistance.
 6. The modularsurgical instrument system of claim 5, wherein the security responsecomprises at least temporarily deactivating at least one of power andcommunications within the modular configuration.
 7. The modular surgicalinstrument system of claim 2, wherein the control circuit is configuredto determine at least one of a connection status and an authenticationstatus of at least one of the modular components of the modularconfiguration based on a magnitude of a deviation between an expectedvalue and a determined value of the total sensed resistance.
 8. Amodular surgical instrument system, comprising: modular componentscharacterized by unique identifier resistances, the modular componentscomprising: a shaft; a handle assembly releasably couplable to theshaft, wherein the handle assembly comprises: a disposable outer housingconfigured to define a sterile barrier, the disposable outer housingcomprising: a first housing-portion; and a second housing-portionmovable relative to the first housing-portion between an openconfiguration and a closed configuration; and a control inner corereceivable inside the disposable outer housing in the openconfiguration, wherein the disposable outer housing is configured toisolate the control inner core in the closed configuration; a loadingunit releasably couplable to the shaft, wherein the loading unitcomprises an end effector; and a staple cartridge releasably couplableto the end effector; and a control circuit electrically couplable to themodular components, the control circuit configured to: detect a modularconfiguration of the modular surgical instrument system based on theunique identifier resistances; and assess authenticity of the modularconfiguration.
 9. The modular surgical instrument system of claim 8,wherein the control circuit is configured to assess the authenticity ofthe modular configuration based on a comparison between expected anddetermined values of the unique identifier resistances.
 10. The modularsurgical instrument system of claim 8, herein the control circuit isconfigured to compare a magnitude of a deviation between expected anddetermined values of the unique identifier resistances.
 11. The modularsurgical instrument system of claim 8, wherein the control circuit isconfigured to determine at least one of a connection status and anauthentication status of at least one of the modular components of themodular configuration based on a magnitude of a deviation betweenexpected and determined values of the unique identifier resistances. 12.The modular surgical instrument system of claim 8, wherein the controlcircuit is configured to select a security response based on a magnitudeof a deviation between expected and determined values of the uniqueidentifier resistances.
 13. The modular surgical instrument system ofclaim 12, wherein the security response comprises a temporarydeactivation of one or more aspects of the modular surgical instrumentsystem.
 14. A modular surgical instrument system, comprising: modularcomponents characterized by unique identifier resistances, the modularcomponents comprising: a shaft; a handle assembly releasably couplableto the shaft, wherein the handle assembly comprises: a disposable outerhousing configured to define a sterile barrier, the disposable outerhousing comprising: a first housing-portion; and a secondhousing-portion movable relative to the first housing-portion between anopen configuration and a closed configuration; and a control inner corereceivable inside the disposable outer housing in the openconfiguration, wherein the disposable outer housing is configured toisolate the control inner core in the closed configuration; a loadingunit releasably couplable to the shaft, wherein the loading unitcomprises an end effector; and a staple cartridge releasably couplableto the end effector; and a control circuit electrically couplable to themodular components, the control circuit configured to: detect anidentification signal of a modular configuration of the modular surgicalinstrument system; measure a characteristic of the modularconfiguration; determine an authentication key based on at least onemeasurement of the characteristic of the modular configuration; andauthenticate the identification signal based on the authentication key.15. The modular surgical instrument system of claim 14, wherein thecontrol circuit is configured to determine the authentication keyindependently of the identification signal.
 16. The modular surgicalinstrument system of claim 14, wherein the authentication key is basedon a characteristic common among individual modular components of themodular configuration.
 17. The modular surgical instrument system ofclaim 16, wherein the characteristic is an environmental characteristic.18. The modular surgical instrument system of claim 16, wherein thecharacteristic is selected from the group consisting of a location, aradio-frequency (RF) intensity, a sound level, a light level, a magneticfield strength, and combinations thereof.
 19. The modular surgicalinstrument system of claim 14, wherein control circuit is configured toutilize the authentication key to decode the identification signal. 20.The modular surgical instrument system of claim 14, wherein theauthentication key is based on a magnetic field strength measured by themodular configuration.
 21. A modular surgical instrument system,comprising: modular components, comprising: a shaft; a disposable handlehousing releasably couplable to the shaft; a control inner corereceivable inside the disposable handle housing, wherein the disposablehandle is configured to define a sterile barrier around the controlinner core; and a loading unit releasably couplable to the shaft,wherein the loading unit comprises an end effector; and a controlcircuit electrically couplable to the modular components, the controlcircuit configured to: generate an interrogation signal; detect aresponse signal to the interrogation signal; determine a modularconfiguration of the modular surgical instrument system based on theresponse signal; and assess authenticity of the modular configurationbased on the response signal.
 22. A modular surgical instrument system,comprising: modular components characterized by unique identifierresistances, the modular components comprising: a shaft; a handlereleasably couplable to the shaft, and a loading unit releasablycouplable to the shaft, wherein the loading unit comprises an endeffector; and a control circuit electrically couplable to the modularcomponents, the control circuit configured to: detect a modularconfiguration of the modular surgical instrument system based on theunique identifier resistances; and assess authenticity of the modularconfiguration.